ML20198H277

Summary of 970313 Meeting W/Bg&E & AP&L in Bethesda,Md Re Reactor Coolant Pump Seal Cooling Following Loss of Offsite Power

ML20198H277
Person / Time
Site:	Calvert Cliffs, Arkansas Nuclear
Issue date:	03/20/1985
From:	Jaffe D NRC
To:	NRC
References
NUDOCS 9709170209
Download: ML20198H277 (31)

Text

.. . _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ - _ - _ - _

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Docket Nos. 50-317, 318 March 20, 1985 SD3/ Y and 50-368 6

LICENSEES:

Baltimore Gasand Arkansas Power and Electric Light (BG&E)

Company Company (AP&L)

}

g go g FACILI, TIES: Calvert Cliffs Units 1 nd 2 v "'

Arkansas Nuclear One, U ,os2' , ,,

SUMMARY

OF MARCH 13 B LETING WITH BG&E AND APal ON REACTOR COOLANT PUMP (RQPt)M640fMA606R. LOWING LOSS OF OFFSITE POWER

'b5 k 24 bi 6 On March 13,1985, . representatives of t*,e NRC staff, BG&E, AP&L and their consultants met in Room P422 in the Phillips Building in Bethesda, Maryland to discuss the cooling of RCPs following a loss of offsite power (LOOP).

Enclosure 1 contains a list of attendees.

Following brief introductory remarks, a presentation was made by Combustion Engineering. A copy of the material presented is shown in Enclosure 2. The presentation described the Byron-Jackson type pump seal in detail and described the adequacy of seal integrity without cooling following a pump trip. A representative from BG&E sumarized the conclusions of the presentations (seeEnclosure3).

Following the presentation, the staff questioned the apparent precccupation of operators with restoring the RCP seal cooling folleting pump trip. A representative of BG&E suggested that this was most likely an economic factor since degraded RCP seals would lead to an extended outage. The NRC staff requested BG&E and AP&L to review procedures and interview operators to detennine if concerns related to RCP seal cooling could distract operators from more important activities during a LOOP or other situation where RCP -

seal cooling is lost. This infonnation is to be distributed to the NRC technical review branches via the NRC Operating Reactor Project Managers.

N David Jaffe, Project Manager Operating Reactors Branch No. 3, OL' '

~ ~

Distribution:

Docket File Meeting Sumary File DJaffe f ORB I f []. 85 3 .20 ( 0 ,

a /

9709170209 970320 '

PDR ADOCK 05000317 P PDR gt, - $l 3 [

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, Enclosure 1 List of Attendees NRC BG&E D. Jaffe R. Ash ., -

D. Herman J. Petro i, . Vassallo D. Elkins -

R. Lee , S. Darling J. Guttmann B. Montgomery W. Kennedy

' B.-Sheron AP&L

-d- A. Rubin J. Jackson D. James

~. ' G..Vissing J. Smith D. Howard W. Garrison Brookhaven National Laboratory

' W. Lukas R. Youngblood

• A. Tingle Other S. Watson ' -

R. Burski R. Houston '

R. Borsum D. Morris J. Waters J. Westhoven R. Hoofewerff S. Mitra '

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- _ _ _ _ _ _ _ _ _ . _ \

, Enclosure 2 i

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1 REACTOR COOLANT l...

! PlJMP r

SEAL -

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r DESIGN I

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E em l PERFORMNCE f

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RC PUf!P DESCRIPT10fl .

SEAL DESIGN AND OPERATION

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SEAL OPERATING LitilTS

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SEAL PERF0PJ1ANCE AND EXPERIENCE -

SEAL TEST PfjoGRAt1S ,

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1 REACTOR C00LA4T PlMP DESCRIPT104 RCPUMP IS VERTICAL, SINGLE STAGE, CENTRIFUGAL PUMP WITH BOTTOM SUCTION AND HORIZONTAL DISCHARGE.

g. 9 SHAFI IS SEALED BY MJLTl STAGE CONTROLLED LEAKAGE F2CHANICAL SEALS.

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4 REACTOR COOLANT PUMP SEALS BYRON JACKSON (B-J) PUMPS UTILIZED AT BOTH CALVERT CLIFFS AND ARKANSAS NUCLEAR ONE (AN0)

PL\NTS

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B&'UB-J PUf1PS INSTALLED AT AND UNIT 1 USE THREE FULL PRESSURE l1ECHAlllCAL SEALS C-E/B-J PullPS INSTALLED AT AND UNIT 2 Al!D

CALVERT CLIFFS UNITS 1 & 2 USE SAfiE SEAL ARRANGE-f1ENT WITH ADDITION OF VAPOR SEAL AB0VE Tl!REE FULL PRESSURE SEALS -

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Cooling Drain 1 L jhf~ Bleed-Off - -

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Closure

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i BASIC $EAL ELEMENTS.

i MECHA11 CAL OR FACE TYPE SEALS - -

! - TWO CO-ACTING SEAL SURFACES, ONE STATIONARY THE OTHER ROTATING.

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- SEAL FACES IN CONTACT, LUBRICATED BY FILM 0F CONTROLLED LEAKAGE.

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- SEAL FORCE DEPENDS ON DIFFERENTIAL PRESSURE ACTING ACROSS FACES. , ,

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- TWO C0-ACTING SEAL SURFACES, ONE STATIONARY THE OTHER ROTATING. '

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- SEAL FACES NOT INDIRECT CONTACT. -

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- DESIGN BASED ON FORMATION OF THIN FILM 0F LUBRICANT 3 WATER BETWEEN SURFACES. -

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% J BJ REACTOR COOLANT PUMP SHAFT SEAL CARTRIDGE

SEAL SYSTEM DESCRIPTION

. B-J P N S THREE MECHANICAL SEALS MOUNTED IN SERIES REDUCE SYSTEM PRESSURE TO VOLUME CONTROL TANK (VCT) PRESSURE.

4 g.

EDUAL PRESSURE DIFFERENTIAL MAINTAINED ACROSS EACH SEAL BY CONTROLLED BYPASS LEAKAGE SYSTEM.

e EACH SEAL DESIGNED TO WITHSTAND FULL SYSTEM PRESSURE SHOULD OTHER SEALS MALFUNCTION, e

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VAPOR SEAL BACK UP VAPOR SEAL LOCATED AB0VE MECHANICAL SEALS TO

,,., PREVENT 0001D OR GASEOUS LEAKAGE FROM ESCAPING TO -

CONTAlmENT.

NORMALLY OPERATED AT VCT BACKPRESSURE.

BUT CAPABLE OF SEALING AGAINST FULL SYSTEM PRESSURE WHEN PIMP IS SHUTDOWN AND DURING,C0ASTDOWN. ,

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SEALMATERIAQ 1

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THREE FULL PRESSURE SEALS AND VAPOR SEAL USE SAME

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MATERIALS

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- ROTATING FACE - TITANIUM CARBIDE SECONDARY STATIC SEALS (ACC0ffiODATE AXIAL MOVEENT OF,ROTATINGASSEMB.lES)

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RINGS & U-CUPS

- ETHYLENE PROPYLENE (EPR)

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' FACE RING SHAFT RING- '

SLEEVENe y ' TING ROTA FACE 3

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,.q VAPc% SEAL Ju_ l_j cgypp/zp 25 psig Midi.

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i SEAL C00Uf6 REACTOR COOLANT WATER COOLED BY INTEGRAL PUMP

, y, HEAT EXCHANGERS BEFORE IT ENTERS SEALS.

TEMPERATURE REDUCED FROM 550*F To 125 - 150'F.

SOURCE FOR COOLING IS COMPONENT C03 LING WATER (CCW) SYSTEM.

COOLED REACTOR C00LAMT BECOMES CONTROLLED LEAKAGE -

AS IT PASSES THROUGH SEAL SYSTEM.

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C0tlTROLlFD LEAKAGE

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' ' CONTROLLED LEAXAGE LUBRICATES SEAL FACES LESS inrd 1% OF TOTAL FLOW CONTROLLED LEAKAGE FLOWS THROUGH ORIFICES MOUNTED PARALLEL TO EACH SEAL TO PR0llDE UNIFORM PRESSURE BREAKDOWN ACROSS EACH SEAL STAGE.

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COUR0LLE0 LEAKAGE NORMALLY,10 GPM AMD COLLECTED INVCT. .

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RCP SEAL INSTRUMENTATION l i CON 1 ROLLED LEAKAGE FLOW RATE ESTABLISHES SEAL- FAILURE SEAL CAVITY PRESSURES - LOWER MIDDLE ALLOWS OPERATOR TO UPPER

.. . AMilCIPATE SEAL PROBLEMS VAPOR SEAL WATER TEMPERATURES - LOWER SEAL -

CAVITY ALLOWS OPERATOR TO CONTROLLED ANTICIPATE SEAL PROBLEMS LEAKAGE OUTLET

• b+  % -

DISPLAYED AND ALARMED IN CONTROL ROOM TO WARN OPERATOR OF POS SEAL PROBLEMS.

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PIMP EQUIPPED WITH VIBRATION MONITORING SYSTEM TO WARN OPERATO ANY EXCESSIVE VIBRATION WHICH COULD CAUSE SEAL PROBLE%.

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SEAL Fall' IRE DEFINITIONS SEALFUNCTIONMAINTAINED ' ' '

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ONE OR MORE OF THREE FULL PRESSURE SEALS FAILS, VAPOR SEAL FUNCTIONS AND DIRECTS CONTROLLED LEAKAGE TO VCT o FAILED SEAL CONTROLLED LEAKAGE FLOWS (B-J) 10F 3 FAILS > 10 GPM 2 0F 3 FAILS 4 2 0 GPM

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3 0F 3 FAILS > 2 0 GPM

< 10 0 GPM'

• EXCESS FLOW CHECK VALVE CLOSES . .

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IF 2.OF 3 SEALS Fall PUMP SHlITDOWN FOR SEAL REPLACEMENT NO GROSS SEAL FAILURE - LEAKAGE DIRECTED TO VCT -

VAPOR SEAL FUNCTIONS

SEAL FAILURE DEFINITIONS liYP0THETICAL COMPLETE LOSS OF SEAL FUNCTION (GROSS' SEAL L;EAKAGE)

PRERE0VISITESi -

FAILURE OFTilREE FULL PRESSURE SEALS FAILUP.E OF VAPOR SEAL

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FAILURE - INABILITY OF SEAL TO HOLD PRESSURE ,

CONSEQUENCES:

4 LEAKAGE PAST VAPOR SEAL MAY BE IN EXCESS OF 0$E CHARGING .

,. , PUMP CAPABILITY (40 GPID -

NOTE:

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COMPLETE LOSS OF SEAL FUNCTION HAS NOT HAPPEMED IN C-E PLANTS E

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l RCPINP i SEAL OPERATING LIMITS INC10ENTt LOSS OF CCW (PUMPS RutlNING) w- '

OPERATING TIME EFFECT ON SEALS 10 Mih. OR LESS 40 DA'%GE -

. N0 INSPECTION AFTER RESTORATION OF CCW.

. REPETITIVE i)CCURENCES MAY '

CAUSE SEAL MALFutlCTION .

30 MIN. MAXIMUM . NO LOSS OF SEAL FUNCTION

. INSPECTION RECOMMENDED

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PRIOR TO PuriP RESTART

. NOT A SAFETY ISSUE l o s.

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RCPUMP t

SEAL OPERATING LLMIS. .

INCIDENTt LOSS OF 0FF SITE AC POWER PUMPS C0ASTDOWN, CCW LOST '

TIME WITHOUT CCW

, EFFECTONSEALS 10 MIN OR LESS

. NO DAMAGE

. N0 INSPECTION

' . PUMPS CAN BE RESTARTED ,

. 4 GREATER THAN

. NO LOSS OF SEAL FUNCTION 10 MIN. AND UP

. VAPOR SEAL HOLDS TO 50 HOURS.

. CONTROLLED LEAKAGE INCREASE DEPENDENT ON TIME . .

. INSPECTION RECOMMENDED PRIOR TO RESTART

{

. IF EVENT LAST SEVERAL HOURS RECOMMEllD SEAL REPLACEMENT

, . NOT A SAFETY ISSUE

1

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RC PUMP SEAL RELIABILITY EXPERIENCE SURVEY OF OPERATING CE PLANTS DONE IN 1981 AS PART OF CI/ DOE SEAL IMPROVEMENT PROGRAM INFORmTION GATHERED INCLUDED:

g. 9

. SEAL LIFE

. FAILURE DESCRIPTIONS -

. OPERATlWG EXPERIENCES

. RADIATION DOSES DOE TO SEAL MINTENANCE .

. MAINTENANCE METHODS AND PROCEDURES 9 .

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PLANT VISITED -

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' LIMITED TO C-E PLANTS MILLSTONE 2 MAINE YANKEE ST.LUCIE1 .

CALVERT CLIFFS 1 & 2 FORT CALHOUN ARKANSAS UNIT 2 PAllSADES WAS IN REFUELING SHUIDOW 9

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. -, . . -m-w,-m, . - . - - , . , - my+m . .u . -

SEAL PERF0P.fMNCE - SutlilARY

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OVERAll AVERAGE IS 13 2 MONTHS OPERATION.

~ ^ '

RANGE 0 TO 54 MONTHS PLANT AVERAGE 10 5 TO 18 5 MONTHS PLANTRECORDSACCESSED:

MAINTENANCELOGS 6

RADIATION WORK PERMITS MAJOR 0lJTAGES DEDUCTED OPERATION PRIOR TO COMERCIAL OPEoATIONS DATE E:

.y -

1

.n -

l

^

RCP SEAL PERF0PJWICE -

MONTHS OF OPERATING TIME

+ INDICATES STILL OPERATING F E G B .C A D Avo. REPLACENEllT Title 10.5 14.7 11.8 18.5 18.0 11.5 MINIMUM 10.7 0 5 0 1 1 0 1 MAXIMUM 32 37 41 54 36+ 23 16+

NUMBER OF SEAL CHANGES: AT RE- -

FUELINGS 1 4 7 4 2 7 0 LESS THAN 1~ CYCLE, '

!.E. < 30 MO. 10 8 14 5 '2 8 2 TOTAL IN SAMPLE 19 19 23 14 8 20 6  :

APPROX. YEARS OF. ,

PLANT OPER. 5 7 9 , 6-1/2 4-1/2 6- 1 1/2 OVERALL AVERAGE - ALL PLANTS 13.2 MONTHS OF OPERATION

+ i 2 AS OF 4/83 - 200+ YEARS OF PU*!P OPERATION HITH0tT LOSS OF SEAL FUNCTION ASOF3/85-50+ADDITIONALYEARSOFDUYOPERATIO*l

'ilTil00T LOSS OF SEAL FUNCTION 4

~ ' ._

AL PERFORMANCE 1 JAIE 10 1983

~

PLANT A PLANT B -C M i

-REPLACEfNT '

1 4TERVA S 1981 1985 (MONTHS) 1981 1985 AVERAGE -

11 5

..-, 17 0 18 5 23.5 MINIMUM. 0 0 1 1 MAXIMUM 23 28 54 63 PLANT C Cch "\

PLANT D AM 1981 1985 1981 1985 AVERAGE 18 0 21 8 - 10-7 18 2 MINIMIM 1

.. 1 -

' 1 1 MAXIMUM 36+ 65 16+ 48 -

4 4 PLANTS REPLACEENTINTERVALS 1981 - 14 5 MONTHS. .

• OVERALL AVERAGE SINCE PLANT START UP 1985 - 19 7 MONTHS g

P

i LOSS OF CCW EVENTS 4

CE OPERATING PLANTS EVE!1T A:

1974'8 1975 - SEALS CHANGED IN ALL FOUR PUMPS -

AFTER LOSS OF CCW INCIDENT 1931 - PUMPS REMAINED ON HOT STANDBY FOR 4 DNE HOUR AFTER LOSS OF CCW. PUMPS

RESTARTED WITHOUT SEAL PROBLEMS

.EVEtiT B:

1977 & 1980 - REPLACED ALL FOUR SEALS ON TWO .

OCCASIONS WHERE CCW WAS LOST '

- 1980 INCIDENT INVOLVED A NATURAL CIRCULATION C00LDOWN BECAUSE CCW

[

3 COULD NOT BE RESTORED e NO COMPT.ETE LOSS OF SEAL FUNCTION OCCURED DURING

,2

4 -

LOSS OF CCW EVENTS C-E OPERATING PLANTS l EVENT Ct ~

1984 - .

2 0F 4 PJMPS PJ.MAINED ON HOT STANDY FOR APPROXIMATELY SIX HOURS WITHOUT CCW SEAL TEMPERATURE REACHED IN EXCESS OF 350*F PRIOR TO RESTORATION OF CCW UPON PWP RESTART SEALS IN ONE PWP OPERATED NORMALLY PROPERLY BUT RECOVERED COMPLETE -

NO EVIDENT INCREASE IN NORMAL OPERATING SEAL LEAKAGE SEALS IN BOTH PUMPS REPLACED DURING 1985 REFUELING OUTAGE INSPECTION RESULTS NOT AVAILABLE YET SEALS IN BOTH PUMPS WERE IN OPERATION FOR 10 AND 12 MONTHS PRIOR TO EVENT

RCP SEAL INTEGRlTY )

(ABORMAL EVENT)

EVEllT D: - -

~

1984 - SHAFT / IMPELLER SEPARATION OCCURRED ON ONE PlHP

-WHILEAT60%POWERLOWERANDMIDDLESEALS FAILEDSIMULTANE0USLY

- PLANT SHUTDOWN COMMENCED AND AFTER TWO HOURS UPPERSEALFAILED '

- AFTER THREE HOURS AFF,ECTED PUMP SECUR,ED

- DURING ENTI.9E EVENT VAPOR SEAL FUNCTIONED -

TO PREVENT GROSS LEAKAGE 10 CONTAlmENT

- EVENT CONFlRMED CAPABILITY OF VAPOR SEAL T0 MINTAIN SEAL SYSTEM INTEGRITY ' '

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4 j

i -

t LOSSOFCCWFVESTS C-EOPERATINGPLANTS

~

RECENT EVENTt .

FEB.1985 -

CONTAINMENT SPRAY ACTIVATIONCCW

.m -

' ATTEMPTS 10 RESTORE CCW TO 3 0F 4 PUMPS SUCCESSFut S0 THESE PUMPS WERE TRIPPED MINUTES TO CONTAINMENT FROM ONE P APPROXIMATELY 3 GPM '

PLANT BUTiU)WER, FAILED INSTRlHENTATION SHOWED MIDDLE AND VAPORTHAT SEALSUPPER FUNC AND PLANT WAS COOLED DOWNSEALLEAK

- 4 GROSS LEAKAGE TO CONTAIMENTDURING .

MAINTALN SEAL SYSTEM INTEGRITYEV ' '

.s e e

'. . ; j 4

l 1

SEALTESTPROGRAMS 4 . .

1 30 MINUTE LOSS OF CCW TEST l

.-.. - RUN ON PRODUCTION PUMP IN B-J TEST LOOP ATPLANTOPERATINGCONDITIONS '

- SEAL FUNCTION MAINTAINED PRESSUREBREAKDOWNSWITHINDESIGNllMITS .

MAX CONTROLLED LEAKAGE 18F GP!)

MAX VAPOR SEAL LEAKAGE 0 5 GPM e e

- PUMP RAM FOR 2-1/2 HOURS AFTER RESTORATION OF CCW SEAL LEAKAGE RATES RET $NED TO NORMAL,

- POST TEST INSPECTION SHOWED A CRACKED VAPOR SEAL ROTATING RING n ~

OTHER SEAL FACES NOT DAMAGED SOMEDETERIORATIONOFELAST0MERS t

- TEST CONFIRED CAPABILITY OF PUMP AND SEALS' TO WITHSTAND A (OSS OF CCW 7 ~

= -- - _ . - .- - - .-. . . . _ - - . -

i SEAL TEST _PROGRA'$

2 LOSS OF ALL AC POWER TEST (STATION BLACK 0

- RUN 04 PRODUCTION SEAL CARTRIDGE UNDER PLA'll H T STANDBY CONDITIONS

- DURATION OF TEST IN EXCESS OF 50 HOURS

- SEAL FUNCTION MAINTAINED CONTROLLED LEAKAGE REMINED WITHIN 110RMAL LIM I ,

, MAX VAPOR SEAL LEAKAGE 0 25 GPM -

- POST TEST INSPECTION SHOWED A CRACKED VAPOR ,

ROTATINGRING PERI %NENTCOMPRESSIONOF0-RINGS 4  %

.W PERMANENTHARDENINGOFU-CUPS

,- TEST CONFlRTED CAPABILITY OF SEALS TO WITHSTAND STATION BLACK 0UT A~

i 1

kb$

Enclosure 3 l

SL'MMARY SEAL IflTEGRITY

~~'

e (10 OPERATillG CE OR BZW PLANT WITH B-J PUMP EVER EXPERIENCED A SIGNIFICAf1T DEGRADAT SEALS DUE TO A LOSS OF CCW INCIDENT e

LOSS OF CCW INCIDENTS HAVE NOT RESULTED IN A LOSS OF SEAL FullCTION e

, BYRON-JACKSON RCP SEAL CAPABILITIES AtlD INTEGRITY CONFlRMED BY SPECIAL TESTS ON PRODUCTION OPERATiflG EXPERIENCE e

LOSS OF RCP SEAL INTEGRITY DUE TO LOSS OF NOT A SAFETY CONCERN '

9

a .

BASES FOR Cl0SIRG II.K.2.16 AND II.K43.2

, (EFFECTOFLOSSOFACPOWERONPUMPhEA

' 9 SEALS ARE CAPABLE OF MAINTAINING FU TO A STATIC PUMP '

L'ING' 4 ,

SINCE CONCERN WAS FIRST RAISED:

{ -

GENERAL SEAL PERFORMANCE HAS IMPROVED 1 k -

EXPECTED TO DECREASE FURTHERLOO 4

- PROCEDURES AND TRAINING HAVE BEEN UPGR

. ,DUE TO LOSS OF COOLINGNO EVENTS-!NDICATING S

(

EXTENDED LOSS OF COOLING WIT CONSEQUENCES

{  !

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SEAL PERFORMANCEOPERATORS HAVE ADEQUA '

4

' 9 .

FURTHER SEAL DES!GN IMPROVEMENTS IN SEAL LIFETIME i

4 ACTIONS INVALIDATE TO / ENVELOP RESOLVE AUTOOTHER COOLING GENERIC ISSUES C '

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MANPOWER AND MATERIAL COSTS COULD BE SIG 4

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