ML20151V587

Rev 1 to Sys Engineering Action Plan SYSTEM-012, CRD Breaker Action Plan

ML20151V587
Person / Time
Site:	Rancho Seco
Issue date:	04/02/1988
From:	Fraser R, Jackie Jones SACRAMENTO MUNICIPAL UTILITY DISTRICT
To:
Shared Package
ML20151V543	List: ML20151V540 ML20151V587 ML20151X287 ML20151X321
References
SYSTEM-012, SYSTEM-12, NUDOCS 8805030114
Download: ML20151V587 (16)

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SYSTEM ENGINEERING ACTION PLAN FOR RANCHO SECO NUCLEAR GENERATING STATION SACRAMENTO MUNICIPAL UTILITY DISTRICT l

l Report No. .jy(fLTJJi.-JLU2 l Revision No. __d._____

Date ___3 39 Y______

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SUBJECT:

CONTROL ROD DRIVE BREAKER ACTION PLAN )

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Prepared by: ____ _ _

System Engineer l

Reviewed byt __,

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l Approved by: ___ _ { ____ . _______________ ,

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Systems Superintendent Approved by: _ _[ _ _______

[ (___ '

1 nt Per ormance Manager j/

I Distribution: J. Vinquist D. Keuter D. Brock

8. Kemper J. Fir 11t G. Cranston J. McColligan Scheduling Outage Manager  ;

RIC Files i

8805030114 OBOhbg12 PDR ADOCK O PDR G

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• CONTROL ROD DRIVE BREAKER ACTION PLAN 1.0 PURPOSE AND SCOPE To establish a course of action to be taken to determine the root cause of the failure of the Control Rod Drive Breaker Undervoltage Device.

To ensure that there are two AC and four DC fully qualified CRD circuit breakers. ,

2.0 ISSUES O Failure of the Control Rod Drive Circuit Breaker #3 undervoltage device (UVD). ,

O Qualification of Control Rod Drive circuit breaker replacement parts.

I 3.0 SHORT TERM CORRECTIVE ACTIONS O Trim the CRD circuit breaker undervoltage device l nameplates. 1 Action by: Don Yount Due by: 3/26/88 - COMPLETED O Perform detailed inspection and testing of the failed UVD.

Action by: Don Yount Due by: 3/27/88 - COMPLETED 0 Inspect the UVDs on all installed CRD circuit breakers.

Action by: Don Yount Due bys 3/28/88 - LOMPLETED I

I O Procure qualified replacement UVDs.

Action by: Tom Redican Due by: 3/28/08 (tentative) ,

I This short term action item has been DELETED.

We are no longer seeking replacement UVDs from Arkansas. Replacement UVDs will be shipped from Wyle Labs (See Long Term Action item).

O Provide interim qualification of installed CRD circuit breakers.

Action by: May Basu a Due by: 3/27/88 - COMPLETED

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• O Rcpleco-tho UVDs on tho innto11cd CRD circuit brockcro as required.

Action by: Don Yount Due by: 3/28/88 (contingent on qualified -

spare UVDs)

This item is COMPLETED. Only one UVD needed to be replaced and a UVD off a spare breaker was used for that replacement.

O Revise EM-175 to incorporate lessons learned. J 1

Action by: John Phipps Due by: 3/27/88 - COMPLETED 0 Perform EM-175 on all insta.11ed CRD circuit breakers.

Action by: Don Yount Due by: 3/29/88 - COMPLETED 1

0 Perform a root cause' determination.

John Phipps Action by:

Due by: 3/28/88 - COMPLETED 0 Perform a work request history review.

Action by: Mike Reale Due by: 3/27/88 - COMPLETED Perform an industry experience review.

I 0 l Action by: Bob Fraser 3/27/88 - COMPLETED l Due by: l i

0 Perform Surveillance Procedures SP.406A/8/C/D as required.

Action by: Charlie Linkhart Due by: 3/29/88 - COMPLETED 0 Make final determination that the installed CRD ciruit breakers are qualified to support criticality.

Action by: Bill Kemper Due by: 3/29/88 - COMPLETED 0 Issue a preliminary report.

Action by: Jeff Jones Due by: 3/28/88 - COMPLETED 4.0 LONG TERM CORRECTIVE ACTIONS O Review adequacy of the CRD circuit breaker trending program.

Action by: Bob Fraser Due by: 5/1/88 O Final qualification of CRD circuit breaker installed UVDs.

Action by: May Basu Due by: 4/15/88

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. O Ccmpleto qualification of encro UVDs.

> Action by: Moy.Basu Due by: 5/1/88 O Procure additional qualified UVDs. l l Action by: Tom Redican i Due by: 4/1/88 (tenative) 10 new UVDs are being sent to Wyle Labs for l qualification and may arrive by 4/1/88. (

0 1ssue final report.

Action by: Jeff Jones Due by: 4/15/88 5.0 SCHEDULE O Short term actions will be completed by 3/29/88.

O Long term actions will be completed by 5/1/88.

6.0 R'ESOURCES O Manpower l 1 Project Engineer l 0

0 4 Plant Performance Engineers 0 1 Quality Engineer 1

0 1 Quality Control Inspector  !

l 0 1 Licensing Engineer i O 5 Nuclear Engineering Engineers O 2 Nuclear Engirieering Technicians O Procurement Engineering support as needed O Electrician support as needed 0 1 B&W Representative O 2 GE Representatives O Clerical support as needed 0 Cost O Unde'termined I

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ATTACHMENT II GCA 88-258 NRC Failed Bolt, TDI Diesel G-100B, and generic observation: implication with regard to other previously highly loaded / stressed bolted connections on the TDI Diesels.

Rancho Seco A Joint Action Plan has been implemented by Response: Nuclear Engineering and TDI Mechanical, Report No.

ERPT-M0096, Revision 0, dated March 28, 1988 (attached) in order to preclude future

~ joint / bolting failures on the G-100A and G-100B TDI Diesels. This will be accomplished by identifying potential areas of failure ahead of time. Subsequent bolt changeout or redesign of pipe supportm, etc., within these identified areas will ultimately increase the reliability of the TDI Diesels.

QA During the March 26, 1988 24 hr run of the Involvement: G-100B diesel it was discovered and documented (on an NCR), that (1) one of the (4) four bolts on the B2 turbocharger mounting feet failed.

Quality's acceptance of the run was contingent on the following:

o NDE (MT) on the (3) three remaining turbocharger bolts found no indication of failure.

o NDE (MT) on (8) eight other bolts, in past known areas of high vibration that had not been replaced, and found no indication of failure.

o The PDQ be dispositioned to replace the original turbocharger bolts with B-7 studs.

o The (3) three turbocharger bolts be sent to a lab for a complete evaluation including chemical and physical properties analysis, and a copy will be provided to the NRC upon receipt of the subject report.

The actions noted above demonstrate Quality's recognition of an unsatisfactory situation and are concurrent with the concerns and recommendations provided by the NRC to Rancho Seco management.

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Control Copy No.

4 NUCLEAR ENGINEERING /TDI MECHANICAL JOINT ACTION PLAN FOR RANCHO SECO NUCLEAR GENERATING STATION .

SACRAMENTO MUNICIPAL UTILITY' DISTRICT Report No. ERPT-M0096 REVISION No. O March 28, 1988 Awe Manager, Nuclear Engineering Greg Cranston

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/ Assistant General Ma@ger ,

Technical and Adminhtrative Services l Bob Croley l

Distribuuion: l G. Carl Andognini, Chief Executive Officer, Nuclear l

Bob Croley, AGM, Technical and Administrative Services l Joe Firlit, AGM, Nuclear Power Production Dan Keuter, Director, Nuclear Operations and Maintenance i

i Jim Shetler, Director, System Review and Test Program i John McColligan, Director, Plant Support l Steve Crunk, Manager, Nuclear Licensing Greg Cranston, Manager, Nuclear Engineering Marshall Weaver, Mechanical Engineering Manager Taj Khan, Mechanical / Piping Group Supervisor John Vinquist, Director, Quality Assurance Lee Fossum, Manager, Scheduling and Outage Management Tom Redican, Manager, Material Control l

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EXECUTIVE

SUMMARY

The District has implemented a detailed vibration monitoring program for the TDI diesel generators to )

verify engine baseline vibration and ensure the  !

associated piping systems remain in compliance with the l vibration requirements of ANSI /ASME'OM3-1982. This monitoring program will continue for each scheduled engine surveillance run after restart until vibration ,

, levels are below OM3-1986 or equivalent levels. l Excessive vibration levels experienced in the past that have since been corrected, may have resulted in high cyclic stresses potentially reducing the calculated service life of certain components on the engines and support systems. This problem was highlighted when one i of four bolts on the B2 turbocharger mounting feet was j observed to have failed or have previously failed during 4 testing on March 25, 1988. In response to this potential reduction in service life, the District has 1 adopted this comprehensive bolting and mechanical joint evaluation plan to limit future failures.

1.0 INTRODUCTION

The G-100A and G-LOOB diesels are currently operable and supporting plant restart. Diesel engine vibration j amplitudes are low as originally tested and associated ,

piping vibration has been reduced to accxptable levels. l The TDI Mechanical Joint Action Plan is being implemented to preclude future joint problems on the G-100A and G-100B TDI diesels. This will be carried out by identifying areas of potential failure ahead of time.  !

Subsequent bolt changeout or redesign of pipe supports, )

etc., in these identified areas will increase the i reliability of the TDI diesels. l l

2.0 NUCLEAR ENGINEERING TDI MECHANICAL JOINTS ACTION PLAN The areas of concern on both TDI diesels for possible future joint / bolting failure have been listed in l Appendix "A". They are identified by location, problem, '

existing fix, future upgrade, and reference documents.

These areas have been specifically chosen based on previously high piping vibration amplitude (exceeded OM-3 1982 levels) and previous component failures. The required actions based on this Action plan are. listed in the "Future Fix/ Upgrade" Block of Appendix "A". The following is a summary of those requirements:

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1) complete bolting change outs to higher strength bolts on the G-100A&B turbochargers;

2) replace exhaust shroud support bolting (G-100A) with higher strength bolts;

3) replace bolting at pipe flanges which are at or near anchos points of the system and which previously experienced high vibrations;

4) replace innercooler mounting bolts to engine on G-100A. (previously done on G-100B);

5) evaluate need to remove shroud and redesign jacket water supports.for G-100A as was done on G-1003;

6) replace starting airline supports on G-100A as was done on G-100B;

7) replace engine access cover bolting;

8) design improved turbocharger diagonial strut support; 1

9) reancl'yze and modify piping support systems as required to enhance vibration reduction efforts.

It is nointed out that flanged piping connections in previous high vibration areas are only a concern at l anchor points. Two areas are identified in Appendix l "A", both on the main lube oil system, that fall into '

this category.

ECTE: A detailed visual inspection of welds on the engine mounted piping and associated supports was performed by plant welding engineers on both engines. No further weld i problems were noted.

NOTE: All referenced bolt change outs can be done one at a time without affecting engine ,

operability (excluding CAM / Crankcase Cover ]

bolt changeout, some of which require removal of the engine inner cooler), or appropriate actions will be taken at the j time of change out.  ;

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NOTE: A sampling of bolting from the starting air header, lube oil pot outlet support ,

bracket, and cam shaft / crankshaft cover, among others have been taken and are currently being examined by NDE to provide

, upfront indication of bolting hardware problems in these referenced areas.

3.0 SCHEDULE Implementation of this plan will occur in several phases based on the complexity and manpower intensiveness associated with each phase. The first phase, which has been completed, included the compilation of a list of areas on the engine and support systems where vibration levels in excess of OM3-1982 requirements were experienced in past runs.

This list is included as an attachment. The second phase will include the identification of all fasteners in these areas of concern, followed by procurement of quality Class 1 replacement parts.

Finally, a portion of these fasteners will be replaced with the new parts prior to each scheduled monthly surveillance run over the next 3 months.

Parts availability holds the greatest potential for impacting this schedule.

The next phase of this plan will involve the reanalysis of all mechanical joints in the identified high vibration areas and is scheduled for completion by September 30, 1988. Any joints identified through this analysis that are determined to have an adverse impact on safe operation of the ongine will be repaired immediately. For areas where rated life of the unit may be effected, but near term operations and safety is not impacted, corrections will be completed prior to return to power from the Cycle 8 refueling outage.

The final phase of this Action Plan, as indicated in past discussions with the NRC, involves the reevaluation of all support systems. This effort, along with all identified modifications, will be completed by the end of the cycle 8 refueling outage.

' *, a 4.0 RESOURCES Implementation of this Action Plan will involve the following District commitment of manpower and materials:

1) Nuclear Engineering to determine bolts requiring replacement, any material upgrades to be made, analysis of all high vibration areas for impact on service life, and implementation of a full reanalysis program on the engine support systems.

2) Material control to procure all required change-out fasteners and other hardware.

3) Maintenance to remove and replace all identified fasteners and other hardware.

4) Modifications to fabricate and install any design change enhancements. -

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APPENDIX "A" Page 1 of 4 l

PREVIOUS AREAS OF HIGli VIBRATION OF FAILURE OF TDI DIESEL COMPONENIS G-100A/B FUTURE FIXLUPGRADE REF_ DOCUMENTS / COMMENTS __

AREA / LOCATION PROHLEM/ CONCERN EYJSUNG FIX

1) Turbocharger foot N.H. bolt observed Broken bolt removed On the G100A engine. PDQ 88-032 mounting bolts broken during 24 hr and replaced with All 4 bolts will be CIDR MC172-081B -i run on 2/26/88 on GR 87 Stud / bolt. replaced. Recommend DWG.H17.02.1-591 SH. 1 (G-100A&B). replacement of turbo G-100B engine. Remaining 3 bolts also replaced with mounting bracket /

B7 stud / bolt. support bolts with GR.B7 or A-490 material. (These bolts are identified on CIDR MC-172-0818)

This is for both t G-100A&B.

Pressure Control None Required NCR 6840/6842/6852

2) 3" lube oil line Line and support '

back to sump via cracked due to valves were PCV-10200 and excessive vibration. relocated and lines PCV-10201. were replaced with 1 stainless pipe.

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4 Pipe stpport was '

redesigned.

Cracks at welds due G-100A weld repaired Evaluate need to NCR 6853

. 3) Jacket water remove shroud and I exhaust shroud to excessive and shroud vibration. reinforced with redesign jactat '

(G-100A). water pipe supports structural steel (Exoskeleton) to as was done on G1008

, limit movement. engine. Replace 1 shroud mounting bolts i to bracket support and bracket mouncing bolts j ,

to engine with GR.07 or j

A-490 maiertal.

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APPENDIX "A" Page 2 of 4 PREVIOUS AREAS OF HIGil VIBRATION OF FAILURE OF TOI DIESEL COMPONENIS G-100A/B AREA /LOCAlION PROBI,EH/ CONC [BN EXISUNG FIX FUTURE FIX/UPG_R_ADE REF 00 CUM [NIS6QMM[NIS____

4) Jacket water Cracks at welds due G-1008 shroud Replace bracket tiCR 7852/7881 exhaust shroud to excessive removed and exhaust bolts to engine. ECN-R2870 (G-100B). vibration. pipes insulated, (Brackets used to jacket water lines support shroud and to and from have now support j&cket been blanked or water line) with capped, jacket water GR.87 or A-490 return lines (that material.

used to be supported to shroud) have redesigned pipe supports.

5) Starting airline Supports cracked Supports were Change out scpports OHG. 10ll6-3"-xx SH.4 support 17A-10ll6- (observed during redesigned and at same location on ECN-R2870; FPR#

14 (G-100B) & 24 hr run on G-1008 installed, line G-100A engine. No NCR 7880/7884 17A-10110-15&l6. diesel). vibrations are cracks exist. DHG 10110-3"-xx SH.1 acceptable. Also, three supports on the same line were .

-changed out using certified materials although no cracks were present.

6) G-100A&B camshaft Various bolts were accept.as-is due to Replace all camshaft NCR 7882 and crankshaft found broken when requirement to / crankshaft access access covers. torque checks were remove inner cooler covers with high performed. for bolt access. strength A-490 bolts.

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APPENDIX "A" Page 3 of 4 PREVI0l!S AREAS OF llIGil VIBRATION OF FAILURE OF TDI DIESEL COMPONENTS G-100A/B

.i AREA / LOCATION PRQQLEMLCONQRN EXISIIMG FIX FUTURE FlK!UEGRADE REF DOCUMENIS/COMMENIS _

7) G-1008 intercooler Several bolts were All intercooler Recommend bolts at NCR 7670

, bracket. found to be broken. bracket to engine same location on mounting bolts were G-100A engine be replaced with changed to GR.87

! GR.87 bolts. or A-490 bolting.

3 1 8) G-100A Line broke off Line was replaced None Required ---

j turbocharger oil where it threads with a design ~

i return line to into turbo. configuration change.

l sump. Turbo vibration 9 levels were reduced. '

I This was done on d both G-100A and I G-1008.

9) Turbocharger Cracked at threads. Pipe was replaced None Required ---

l 1/2" threaded and support was

-supply line. added to bring vibration amputudes to an acceptable level.

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10) G-100A shroud Excessive loading Installed flex hose None Anticipated - - - -

jacket water. calculated at jacket at outlet. (This water shroud outlet was also done on nozzle. G-100B diesel but was deleted when the shroud was I removed).

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ATTACHMENT III GCA 88-258 i

NRC. Apparent lack of. vigorous / thorough 50.59 Review Observation: by the PRC of Modifications made to the letdown system.

Rancho Seco Specifically, the NRC's concern directe'd attention Response: to the 50.59 determination which, by charter, need only be reviewed by the PRC Chairman &cting as a sub-committee of one.- The letdown cooler modification exemplified the need for more  :

technical review of ECN'=/50.59's. At a subsequent meeting of the J111 PRC'on March 29, l 1988, the PRC decided and approved formation of a i subcommittee to review all ECN's and the associated 10 CFR 50.59 determinations for approval or, submit to full FRC Committee review ,

i per the requirements of Technical = Specifications i

! 6.5.1.6.(d). The subcommittee will be made up of  ;

j the PRC chairman-and at least one other PRC member i selected by the PRC Chairman as appropriate to the  !

i subject matter of the ECN.

r By May 15, 1988 the Director, Nuclear Operations & i Maintenance will assume the Chairmanship of the  ;

PRC and wembers of the PRC are to be selected from '

those individuals holding positions shown in i Figure 6.2-2 of the Technical Specifications.

System Engineering has initiated an Action Plan, Letdown Cooler Thermal and Hydraulic Shock '

4 Prevention, dated March 29, 1988 (attached). The ,

1 purpose of this Action Plan is to minimize letdown i cooler thermal and hydraulic shock and elim'.nate letdown cooler relief valve lifts. This Action.

Plan encompasses incident analysis, desi3L l changes, testing, operating changes, letdown I system design evaluation, and root cause I investigation.

1 A voluntary LER 88-05, Thermal Hydraulic Shock of Letdown Coolers, is being prepared by Nucl6ar Licensing and will address both relief valve occurrences. The LER will include commitments i

previously made verbally tc the NRC, and are as follows:

I j a) Perform a detailed evaluation of the letdown 1 system to determine if any changes in system i design or operating philosophy are required.

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ATTACIDENT III (continued) i GCA 88-258 b) Update the preliminary Incident Analysis as necessary based on the results of the letdown system evaluation.

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