ML20093K194
| ML20093K194 | |
| Person / Time | |
|---|---|
| Site: | Fort Saint Vrain  |
| Issue date: | 09/24/1984 |
| From: | Gahm J PUBLIC SERVICE CO. OF COLORADO |
| To: | Johnson E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| References | |
| P-84370, TAC-55294, NUDOCS 8410170215 | |
| Download: ML20093K194 (53) | |
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0-public service company e conendo e a 16805 WCR 19 1/2, Platteville, Colorado 80651 September 24, 1984 Fort St. Vrain Unit #1 P-84370
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Mr. E. H. Johnson, Chief Reactor Project Branch 1 .,, 3 M Region IV p Nuclear Regulatory-Commission 611 Ryan Plaza Drive, Suite 1000 Arlington, TX 76011
SUBJECT:
Damaged Control Rod. Removal on Fort St. Vrain Fuel Deck
Dear Mr. Johnson:
This letter is provided as a courtesy to keep you aware of the status i, of the fuel deck at Fort St. Vrain.
- Removal of Control Rod Drive and Orificing Assembly (CRDO ) Serial Number 25 from Region 7 started.on August 29 with retraction of -the control rod absorber strings. The normal "0VT" limit and " FULL RETRACT" indications came up, as occur during a normal CRD0A removal.
Installation of the battery box'and shipping tool (used to hold the absorber strings in position once the CRD motor power- was ' removed) , was done, and the entire mechanism was unbolted. At this point, removal from the PCRV could proceed. The next shift's crew moved the Auxilliary Transfer Cask (ATC) into place over the Reactor Isolation Valve (RIV) and prepared to remove the CRD0A. The mechanism was raised into the ATC with normal indications for weight and other parameters. When the ATC shutters were closed, an overcurrent fuse blew. This was the first indication of a problem. At the same time, the operator noted an increase. in weight from 4900 to about 6000 lbs. The RIV, which had never been completely closed, was reopened, and the ATC Shutters were reopened. . Radiation levels on the fuel deck were typical for this type of evolution. l 1 8410170215 840924 /' I PDR ADOCK 05000267 . 3 :) {D S PDR
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In _a ccordance with normal routine, the Supervisor lowered the CRDOA back into the PCRV to re-evaluate the situation. The mechanism was lowered about 25 feet when a weight loss occurred. Normal position for seating the mechanism is 33 feet. The mechanism was again lifted into - the ATC and consultation with station management occurred. A second attempt to lower the mechanism was made. This . time, weight loss occurred at about 10 feet. The mechanism was raised into the ATC and lowered again, resulting in weight loss at 3 feet. The mechanism was fully retracted and work stopped pending evaluation. Review of the events suggested the absorber strings may not have been fully retracted, despite the " FULL RETRACT" limit switch indication observed during retraction. This indication requires that only one of two redundant switches is made up, on either absorber string full retract assembly. The evidence suggested that one rod fully retracted while the other did not. It was decided to perform a radiation survey around the ATC to look for a skewed level along the rod pair axis, and remove the drive screw from the ATC shutters to allow internal examination by borescope. Radiation survey did indicate a skewed level along the east-west axis. The first borescope examination, through the east' drive screw penetration identified an absorber cannister, but the orientation could not be determined. A second, improved borescope was obtained, and several additional examinations were made from both the east and west sides. One absorber string could be observed during the examination, with the shock absorber from that string bent at a high= angle and positioned near the RIV gate area. The lower cannister also appeared to be creased. From this information, estimates of distance that the lowest section of the string was below the ATC shutter and anticipated radiation levels were made. A test to lift the ATC and actually observe the cannister string using video equipment to veri fy borescope observations and measure radiation levels was developed. Test T-242 was written to accomplish this task and was performed on September 5 on swing shift. Levels in the gap formed between the ATC and RIV were about 7 R/hr, while those in the vicinity of the reactor building crane operator and Health Physics Technician were 20 mR/hr, maximum. In preparation for performing this task, the ATC shutters were intentionally manually closed on the absorber string to guarantee that it would not fall free and create a hazard. Remote viewing capability was provided by TV cameras and remote monitors. Information from Test T-242 was used to determine a procedure for removal of the damaged CRD0A from the reactor. Radiation levels were such that exposure for. personnel " riding" on the ATC (crane operator and HP technician) would be acceptable provided no material was dropped during the transfer.
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e 14-Finally, preparation and removal of the damaged mechanism was done under-Fuel Handling Procedure Work Packet 82. Modifications to existing equipment included a special head for the overhead crane to allow as much as 50 inches of lift, special limit switches for,_this additional travel, remote operatica capability on the RIV, remote viewing cameras and monitors to control _ the work, and a crane operation -station against the body of the ATC, where shielding would be greatest. The transfer was done- such that once the abosrber string was clear -of the RIV, the ATC was moved over a collapsible catch net, which was raised to contain any' falling control rod parts and preclude personnel hazards should-this possibility arise. The hot. cell was set up to receive the damaged CRD0A,'with a funnel-type cone installed in the east port to insure that the damaged string would not hang up during CRD0A installation. The transfer itself (performed on swing shift September 9) was uneventfc1, with no material lost. The catch net was removed when the ATC was positioned over the shield adaptor on the east port of the hot cell, and the ATC was lowered. Nuclear Regulatory Commission Inspectors Plumlee and Chaney were present and cognizant of all activities. When the CRDOA was lowered into the HSF, examination of the mechanism indicated no damage to the main assembly. One absorber string was hanging down, with damaged absorber sections and shock absorber, with about 4h cans evident. The other string was fully retracted as originally suspected. On the_ damaged strings, the shock absorber had about a 150 bend occurring nearly at the top. The lowest three absorber cans had evidence of damage, such as creases, scrapes, and spine bending. Although examination is not complete at this time, all damage observed on the cannister string is consistent with the removal events scenario, i.e., the mechanism damage occurred from (1) closing the ATC and possibly the RIV on the lowest two cans, (2) initially attempting to deposit the CRDOA back into the reactor, (3) attempting to return the CRD0A to the ATC, and (4) repeating attempts to deposit the CRD0A back into the reactor. The shock absorber damage apparently occurred when the weight of the CRD0A was partially placed upon it when it failed to locate correctly in the control rod hole in the top plenum -element. (Note that the damaged string was hanging below the guide tubes normally serving to align the control rod strings with the center element control rod holes.) The cannister creases resulted from closure of the RIV and ATC shutter. Visual inspection of the Region 7 plenum area revealed no damage, although several contact spots may have been observed. There were no abnormalities with regard to plenum element / Region Constraint Device position and placement. Consequently, a replacement CRD0A was installed in the region on September 12.
; ? 4 Test T-244 was written to visually examine the "as found" condition-of the CRD in the hot ' cell after removal. To prevent the disturbance of internal components, the' orifice motor access plates were removed before lifting the CRD 200 Assembly. Both cables could .be seen on the cable drum. One appeared to be in good shape, unaffected, while the other was wrapped around the' cable drum hub assembly. -Pieces of shredded cable' were found on the orifice motor plate. One piece, approximately 12" in length, was found on the plate. .The 200 Assembly was then raised to enable the examinalton of the cable drum hub assembly and shim motor. While this was being done, several pieces of cable fell to the orifice motor plate. A large four to five foot section of cable was found to be wrapped around . the cable drum. This piece of cable'was' jammed in the cable channel at the bottom of the drum. It was also noticed that the outer channel of the cable drum had minor nicks, scratches, and scrapes on its edge.
Photographs of the damaged cannister string and CRD internals are included for your information. If 'you' have any . questions, please contact Mr. Chuck Fuller at (303) 785-2224, Ext. 202. Sincerely, h NSI hr J. W. Gahm Manager, Nuclear Production Enclosure JWG/djm i ,
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(; e 1u P-84370 Attachment 1
. September 24, 1984 PICTURE DESCRIPTION NOTE: Picture' labels A-1 through A-16 correspond to 1 through 16 below.
- 1. View through one of the four orifice motor access plates.
Shiny debris is from damaged cable.
- 2. View through another of the access plates. Damaged cable
.. debris is visible.
- 3. Two pieces of cable-that fell to the orifice motor plate while lowering the control rod absorber string during examination.
- 4. View of the 200 Assembly; cable is on the cable drum hub assembly. The cable should be under the housing (brown cover) in the guide channel.
- 5. View of the 200 Assembly with guide pulley cover visible (brown component below cable drum). Cable is wrapped between slack cable assembly and cable drum.
- 6. View of point where cable wraps were adjacent rather than on top of each other in the cable channel. Notice undamaged cable.
- 7. Another view of adjacent cable wraps.
- 8. View of cable protruding from bottom of cable drum.
- 9. View of cable protruding from bottom of cable drum.
- 10. View of shim metor/ brake assembly and position potentiometer.
No abnormalities.
- 11. Damaged absorber string strung out onto hot cell floor from CRD0A orifice valve assembly guide tube.
The following are sequential pictures moving down the / cannister string to shock absorber.
- 12. Guide tubes showing retracted and damaged absorber string positions.
- 13. -First cannister completely below end of guide tube.
- 14. Second cannister completely below guide tube.
- 15. Third and fourth cannisters completely below guide tube and shock absorber.
- 16. Same as (15), but better shock absorber detail.
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' :* - 3HIM MOTOR AND 296 AIIEMBLY TO BE REftFBIIHED.
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CR904 19 PTR CURRENT LOC: R-25 e4-ee-ee4e . LDC ON 4/23/94 - E2W-3 I.
.+ i
'l . O MORR: . IJ 2 3R-RE-48-X WAK JTARTED AND UPON PREIIURIZATION OF
'I REFUELIIIE PENETRATION 925 THE FRIMARY JEALI LEAKED
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l' r T O 'O CRDOAt 20 ' CURRENT LOC: R-19. ' LOC ON 6/23/84 : ESW-9
-i PTR
- 84-03-9610 84-07-0328 ,
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1' i8 . ,, REPLACE RID HOPPER PREISURE' SWITCH. i . :.i POSITON POT BROKEN - REPLACE. h .:jj: .. REMOVE FROM R-t? BEFORE STARTUP.
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'g, SHIM NOTOR TO BE REFURBISHED - BAD DACK EHF ACCELERATION. *
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WORK: , WHEN POISIBLE. REMOVE COVER FROM REG. 14 TO VERIFY HEAT 3
' DN CRD 24. THE HEAT NUMDER WILL BE VERIFIED AND l 2 ".}h Y? DOCUMENTATION WILL PE UPDATED. THIS DOEI NOT AFFECT THE ) I
- i. OPERABILITY OF THE CONTROL ROD. NOT REPORTABLE. L.B. 8-7-84 i
- O INITALL'IN R-14.
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O CRDOAi 25 CURRENT LOCI.HSr Er LOC ON 6 2se84 R-ia -W PTR . 84-07-0406 , O WORK: . -) *
'j .jj SHIM NOTOR HAS BEEN REFURBISHED.
SLACK CABLE IWITCHES NEED RESETTING. 1
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h .. 2; POSSIBLE PROBLEMS WITH SLACK CABLE. CONTROL ROD DAMAGED IN ATC. , ; CONDUCT TEST T-242. I O CONDUCT TEST T-244. Y 4 )j
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. FAILED TO ICRAM ON 6/23/84. SHIM HOTOR HAS BEEN REFURBISHED. ,
IDENTIFIED ON 7 89/84 AS HAVING A FAULTY ' SLACK CABLE
- O SWITCH. TO BE REMOVED FROM CORE AGAIN TU REPAIR
- SLACK
.i' f, CABLE
- SWITCH. WEST ABSORDER STRING DAMAGED BY ATC SHUTTER ,
{! ON 0-29-94. T-242 CONDUCTED ON 9-5-84 TO DETERMINE RADIATION O LEVELI. CRD MOVED FRON ATC To :ISF ON 9-11-84. BEGAN T-244 DN ' 9-18-84 TEST IS STILL IN PROGRESS.
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' CURRENT LOC: R-7 LOC ON 6/23/04 R-6 ~l PTR ,
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. SHIH HOTOR AND 200 AIIEMBLY TO BE REFURDISHED. t 1 ITUCK ORIFICE VALVE IDENTIFIED ON 6-29-04.
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. CURRENTLCOfR-4 s-LOC ON 6/23/84
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' CURRENT' LOC: 'R-20 LOC ON 6/23/04 . R-20 8 i i
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?I O h CRDOA: 33 PTR . 94-92-365 CURRENT LOC: R-16
' LOC ON 6/23/84 R-16 '8 t
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. FAULTY ANALOG POSITION INDICATION IDENTIFIED ON 7-21-84 f FOUND OPEN IN CRD BETWEEN 2TB 6 & 7, AND 2TB 5 & 6. .
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' CURRENT lDC: R-33 LOC ON 6/23/84
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CURRENT:LOCkR LOC ON 6/23/84 ' R-29 '
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. CRDOA: 36 CURRENT LOC:-R-28.
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. ORIFICE VALVE ITUCK..
r ADJU.sTED TO REMAIN IN THE 170 OHH POSITION - EQUAL FLOW .
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FOR REGION 28. ADJUSTED ON 8-6-84. PROBLEM STILL EXIKTS WITH ORIFICE VALVE. I ' . ,,
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jj STUCK ORIFICE VALVE IDENTIFIED ON 6-29-84.
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' CURRENT LOC: R-23 LOC ON 6/23/84 R-23 1 j.
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i i R.P.I. REGION 23 ANALOG ON I-03 NOT READING PROPERLY. ^ l h .l l.- IN PERFORMANCE OF A SCRAM TEST THE IN LIMIT LIGHT DID NOT GD DUT WHILE PULLING THE ROD OUT IT STAYED ON ALL THE WAY OUT ); l)
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, ,; PTR : 93-04-0106 ,
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] . ANALOG ZI FOR R-35 IS ERRATIC WilEN FIRST PULLED. INCREASES .
j2I. TO' 25' AND DROPS TO ~15'. IT INCREAIES NORMALLY AFTER THAT.
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! REMOVE FRON R-39 BEFORE STARTUP.
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, CURRENT LOC: R-35 04-08-9090-LOC ON 6/23/84 ? R-28 8 I i fO WORK:
WRONG SERIAL NUMBER PAINTED ON THE TOP OF CLOSURE A MEMBLY, 1
,, 2 NEEDS TO DE STAMPED WITH CORRECT SERIAL NUMBER (SS/N 44). i
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TABLE I.D. CRD FUNCTION: N NEXT: CRD 8409212 CONTROL ROD MOVEMENT RECORDS
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'CRD
& 's 8408062 36- FM: -HSF TO: R28 PER FHPWP-75
- s- 8408063 44 FM: E4 TO: HSF PER FHPWP-22 -WHEN PLACED IN; 04080631 44 CONT'D...FIRST THOUGHT TO DE CRDOA044, THEN IT!
00 44 CONT'D...BUT-LATER,-IT WAS CONFIRMED TO DE 444, 00 84080632 ps 8408161 44 FM: HSF TO: E4 PER PTR ? 6-060 u) 8408162 29 FM: E5 TO: HSF PER FHPWP-22 34- 8408231 29 FM: HSF TO: E5 PER FHPWP-22 l 8403232 '7 FM: E6 TO: HSF PER FHPWP-22 LC[", 7 FM: HSF TO: E6 PERFHPWP-22,MP12-12,ANDP{ 840825 840826 11 FM: E3 TO: HSF PER FHPWP-22, MP12-12, AND P1 8408301 25 FM: R7 TO: HSF-EP PER FHPWP-78, FHPWP-82, TH 25 CONT'D...FIRST PUT IN ATC ON 8/30/84, GOT STU 8408302 25 CONT'D..'.INTO HSF ON 9/11/84. ABSORBER STRING 8408303 840913 29 FM: E5 TO: R7 PER MP12-1
- (' 840915 21 FM: R35 TO: E5 PER MP12-1 840917 44 FM: E4 TO: R35 PER MP12-1
;, 0409201 2 FM: R27 TO: E4- PER MP12-1 8409202 11 FM: HSF TO: R27 PER MP12-1 g 0409211 13 FM: E2 TO. HSF PER FHPWP-22 FOR MORE OF THIS LIST, PUSH ENTER AGAIN.
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-( TADLE-I.D. CRD
'CRD CONTROL ROD MOVEMENT RECORDS 25' FM: HSF TO: E5 PER PTR C6-754 o o 8407021 i- 8407022 25- FM: E5 TO: R7 PER PTR C6-859 p- 8407031 18FM: R7 TO: HSF PER PTR 46-859
.. UD 8407141- 18' FN: HSF TO: E5 PER PTR C6-863
~~
P9 8407142 14 FM: Rio TO: HSF PER PTR 46-863
'll) 8407143 18' FM: E5 TO: Rio PER PTR C6-863 MP 8407271 29 FM: R6 TO: E3 PER PTR 46-857 & 6-884 8407311 14 FM: HSF TO: R6 PER PTR C6-857
'LI{i 8408011 7 FN: R25 TO: E6 PER FHPWP-72 8408021 11 FM: R30 TO: E3 PER FHPWP-71 8408022 43 FM: E2 TO: R30 PER FHPWP-73 E3~ TO: R25 PER FHPWP-72 8408023 19 FM:
8408031 13 FM: R19 TO: E2 PER FHPWP-73
.< 8408041 20 FM: E9 TO: Ri9 PER FHPWP-75 8408042 9 FM: E4 TO: E9 PER FHPWP-75 3
4 8408043 36 FM: E7 TO: HSF PER FHPWP-75 7 8408061 44 FM: R28 TO: E4" PER FHPWP-75 FIRST THOUGHT T 84080611 44 CONT'D...WAS CRDOA?44, THEN THOUGHT TO BE CRDOA 3 7 84080612 44 CONT'D...BUT-LATER, THIS WAS FOUND TO BE C44 AT FOR MORE OF THIS LIST, PUSH ENTER AGAIN.
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',( TABLE I.D.. CRD FUNCTION: N NEXT: CRD 8407021 j CRD CONTROL ROD MOVEMENT. RECORDS !
o a 0402271 34 FN: HSF TO: E9 PER'FHPWP-21 (REFUELING) s 840301 34 FM: E9 TO: R33 REFUELING PER FHPWP-21 gg 8403021 10 FM: E2 TO: R5 PER C/N 1742 UD 8403022 20 FM: R5 TO: E9 PER C/N 1742 , r- 840303 43' FM: R35 TO: E2 PER C/N 1742 u) 840304 21 FM: HSF TO: R35 PER C/N 1742 st 840309 5 FM: R22 TO: .HSF PER PTR. 2.-331-84 u? 840311 5 FM: HSF TO: R22 PER PTR 2-331-84 840315 6 FM: E5 TO: HSF PER PTR 43-234-84 840316 HSF TO: Ri NO CMG-12A IS AVAILABLE,
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6 FM: {} S403161 6 CONT'D........SEE PTR #3-243-84 840310 24 FM: Ri TO: E5 PER PTR 43-243-84 840420 24 FM: E5 TO: HSF PER PTR 44-354-84
- 840423 42 FM: E7 TO: HSF PER PTR 42-28-84 & 1-415-84 840426 36 FM: R12 TO: E7 PER PTR i 84-2-28 4 840427 , 42 FM: HSF TO: Ri2 PER PTR ? 2-28-84
; 840509 24 FM: HSF TO: "E5 PER PTR 44-354-84 L 8406271 25' FM: Ri4 TO: HSF PER PTR 46-754 s 8406272. 24- FM: E5 TO: R14 PER PTR 46-754 s FOR MORE OF THIS LIST, PUSH ENTER AGAIN.
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- , CRD. CONTROL ROD MOVEMENT RECORDS
'6 s- 8409212 4 FM: R37 TO: E2 PER FHPWP-80 8409213 7 FN: E6 TO:'R37 PER FHPWP-80
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