ML20206P931

Summary of 870403 Meeting W/Util in Arlington,Tx Re Licensee Discovery That Pressurizer Code Safety Valve Set Above Tech Spec Limits.List of Attendees & Util Presentation Encl

ML20206P931
Person / Time
Site:	Arkansas Nuclear
Issue date:	04/15/1987
From:	Johnson E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:	NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
Shared Package
ML20206P850	List: ML20206P845 ML20206P931
References
NUDOCS 8704210298
Download: ML20206P931 (36)

Text

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MEETING

SUMMARY

Licensee: Arkansas Power & Light Company Facility: Arkansas Nuclear One, Unit 1 License: DPR-51 Docket: 50-313

SUBJECT:

ARKANSAS NUCLEAR ONE, UNIT 1, PRESSURIZER CODE SAFETY' VALVE ENFORCEMENT CONFERENCE On April 3, 1987, representatives of Arkansas Power & Light Company met with Region IV personnel in Arlington, Texas, to discuss the licensee's discovery that a pressurizer code safety valve was set approximately 500 psi above the lift set pressure specification. The attendance list is attached as Appendix A to this summary. The meeting was held at the request of the NRC Region IV office.

The licensee presented a summary of events and the results of their investigations. The root cause has not yet been established by the licensee; however, the review, to date, indicates no apparent incorrect maintenance or testing activities. With the evidence available there is every indication the improper valve lift pressure set point has existed since September 1985.

7A AL E. H. Johnson, Director Division of Reactor Safety and Projects Attachments:

1. Appendix A - Attendees

2. Appendix B - AP&L Presentation (PDR only) i i

8704210298 870415 PDR ADOCK 05000313 S PDR

o APPENDIX A ATTENDEES Enforcement Conference April 3, 1987 AP&L (ANO-1)/NRC Name Affiliation / Title D. Baxter AP&L/ Mechanical Maintenance Engineer M. Browning AP&L/ Nuclear Services Engineer G. Campbell AP&L/Vice President, Nuclear Operations T. Enos AP&L/ Nuclear Engineering & Licensing D. Howard AP&L/Special Projects Manager J. Levine AP&L/ Exec. Director, AN0 Site Operations D. Lomax AP&L/ Plant Licensing Supervisor J. McWilliams AP&L/ Maintenance Manager J. Smith AP&L/ Nuclear Services Engineer D. Hunter NRC/Section Chief, RPS-B E. Johnson NRC/ Director, DRSP W. Johnson NRC/SRRI D. Powers NRC/ Enforcement Officer

a - --,. --a ARKANSAS NUCLEAR ONE PMSSURIZER CODE SAFETY VALVE ENFORCEMENT CONFERENCE APRIL 3, f987

b AGENDA

, BACKGROUND AND SEQUENCE OF EVENTS. . . . . . . . . DAN h0 NARD INITIAL ROOT CAUSE EVALUA TION. . . . . . . . . . . . . DON LGMAX u

CONTINUING INVESTIGA TION AND TESTING. . . . . . J0ln SMITH SAFETY SIGNIFICANCE OF POSTULA TED. . . . . . . . .DA VE BAXTER VAL VE FAILURE CONCLUDING REMARKS. . . . . . . . . . . . . . . . . . . . . . . . GENE CAMPBELL l

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BACKGROUND AND SEQUENCE OF EVENTS l

SAFETY VALVE REQUIREMENTS o TECMICAL SPECIFICATION 3.1.1.3 TWO VALVES REQUIRED FOR CRITICAL OPERATION ONE VALVE REQUIRED FOR SUBCRITICAL OMRATION o TECMICAL SMCIFICATION 2.2.2 MOUIRES VAL VE SETPOINT PER ASME CODE o TECHNICAL SPECIFICATION BASES NOTES SETPOINT TO BE 2500 PSIG t 1%

l 0 TECHNICAL SPECIFICATION 4.1 REQUIRES TESTING ONE VALVE EVERY EIGHTEEN MONTHS l

SAFETY VALVE TESTING o IN-SITU TESTING f

SOLE TEST METH00 PRIOR TO 1982 PER MANUFACTURERS RECONMEi&ATIMS TEST PEAF09MED AT INSTALLED CONFIGIRATION

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AND CONDITIONS i

o DFFSITE TESTING i i PRIMARY METH00 SINCE 1982 PERFORMED AT HOT CONDITIONS WITH STEAM i

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DIRECT MEASUREMENT if LIFT PRESSURE 4

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, ATTACHMEP.'T 2 Pressure Diagram for Use with Hydraulic Setting Device

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__.1 PIESSURE IN HYDRNLIC CYLDCER (GW2 LEADING - PSI)

1R7 SEQUENCE OF EVENTS o PSV-1001 REPLACED WITH SPARE VAL VE PREVIOUSL Y TESTED OFFSITE TO MEET TECHNICAL SPECIFICATION SURVEILLANCE REQUIREMENTS o PSV-1001 TESTED IN-SITU TO CONFIRM OFFSITE SETTING (NOT REQUIRED BY TECHNICAL SPECIFICATIONS) o PSV-1001 FOUND SLIGHTLY LOW ; ADJUSTED o PSV-1002 TESTED IN-SITU TO CONFIRM SETTING (NOT REQUIRED BY TECHNICAL SPECIFICATIONS)

VALVE LIFTED AT APPROXIMATELY 2850 PSIG AFTER ADJUSTMENT OF 10 NUT FLATS VALVE ADJUSTED TO PROPER SETTING ESTIMATED AS FOUND SETTING OF APPROXIMATELY 3000 PSIG o INITIAL ROOT CAUSE INVESTIGATION INCONCLUSIVE NO PRIOR TESTING OR MAINTENANCE ERRORS FOUND

1 iR7 SEQUENCE OF EVENTS (Cont.)

o DECISION TO COOLDOWN AND REPLACE PSV-1002 o FINAL IN-SITU TESTING AND AnJUSTMENT OF REPLACED PSV-1002 (ADDITIONALLY TESTED OFFSITE) o PLANT STARTUP

CURRENT VALVE OPERABILITY a BOTH VALVES WERE TESTED OFFSITE AND IN-SITU DURING 1R7 o IN-SITU TEST PROCEDURES AND METHODS REVIEWED AND WITNESSED BY THE VALVE VENDOR AS WELL AS APGL MAINTENANCE, ENGINEERING AND QUALITY CONTROL o INDUSTRY EXPERIENCE REVIEWED AND DISCUSSIONS WITH VAL VE VENDOR INDICA TE NO EVIDENCE OF GENERIC PROBLEM o SPECIFIC VAL VE IS NOT IN SERVICE h......

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INITIAL ROOT CAUSE EVALUATION

REVIEW OF 1R7 OUTAGE WORK o REVIEW OF TEST PROCEDURE

- PROCEDURE TEST METH00 CONSISTENT WITH TECHNICAL MANUAL INSTRUCTION

- PRESSURE CORRELATION CURVE WAS CORRECT

- TEST DATA REDUCTION PROPERLY PERFORMED o REVIEW OF TEST EQUIPMENT

- PRESSURE GAUGES CALIBRATED {BEFORE AND AFTER)

- CORRECT PRESSURE RANGE HYDROSET MODEL

- SUCCESSFULL Y RETESTED VAL VE IN PSV-1001 POSITION FOLLOWING INITIAL FAILURE OF VALVE IN PSV-1002 POSITION TO LIFT o VALVE VENDOR CONTACTED

- SETPOINT PROBLEM OF THIS MAGNITUDE NOT PREVIOUSL Y OBSERVED FOR IN-SITU TESTING o REVIEW OF OUTAGE WORK IDENTIFIED NO WORK PERFORMED ON VAL VE IN PSV-1002 POSITION DURING 1R7

REVIEW OF PRIOR WORK HISTORY ON VAL VE IN PSV-1002 POSITION o VAL VE IN PSV-1002 POSITION REPLACED DURING 1R6 WITH OFF-SITE TESTED VALVE o VAL VE IN PSV-1002 POSITION REPLACED DURING UNIT SHUTDOWN IN SEPTEMBER 1985

- ON 9/18/85 UNIT SHUTDOWN TO REPAIR A CONTROL ROD DRIVE STATOR

- VALVE IN PSV-1002 POSITION BELIEVED TO HAVE LEAKAGE PAST SEAT

- VALVE IN PSV-1002 POSITION REPLACED WITH APGL REFURBISHED SPARE ON 9/22/85

- VALVE IN PSV-1002 POSITION TESTED ON 9/26/85 FOLLOWING UNIT HEATUP o NO WORK PERFORMED ON VALVE IN PSV-1002 POSITION SUBSEQUENT TO 9/85 AND PRIOR TO 1R7

REVIEW OF SEPTEMBER 1985 WORK o REVIEW OF TEST PROCEDURE

- TEST PROCEDURE REVISED BETWEEN 9/85 AND 1R7

- PROCEDURE CHANGES PRIMARILY ADMINISTRATIVE

- REFORMA TTED TO NEW PROCEDURE STANDARD

- REQUIRES RECORDING VALVE COMPONENT AND SERIAL NUMBERS

- REQUIRES RECORDING LOCATION OF VALVE AND PROVIDES LOCATION DIAGRAM

- PROCEDURE TEST METHOD CONSISTENT WITH TECHNICAL MANUAL INSTRUCTION

- PRESSURE CORRELATION CURVE CORRECT

- TEST DA TA REDUCTION PROPERL Y PERFORMED o REVIEW OF TEST EQUIPMENT

- PRESSURE GAUGES CALIBRATED (BEFORE AND AFTER)

- CORRECT PRESSURE RANGE HYDROSET MODEL

REVIEW OF SEPTEMBER 1985 WORK (Cont.) .

r o POTENTIAL FOR 9/85 TESTING OF WRONG VALVE o TEST PERFORMANCE PERSONNEL (MAINTENANCE ENGINEERS AND MAINTENANCE CRAFTSMEN) STATED BELIEF THAT CORRECT VALVE TESTED o REVIEW OF WORK ENVIRONMENT

- VALVE IN PSV-1002 POSITION FIRST VALVE ACCESSIBLE

- ESTABLISHED VAL VE IN PSV-1002 POSITION LABELLED AS VALVE 'PSV-1002'

- ESTABLISHED VALVE IN PSV-1001 POSITION LABELLED AS VALVE ' SPARE' t

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l SUBSEGUENT REVIENS AND RESUL TS o REVIEW OF REMOVAL AND REPLACEMENT PROCEDURE AND TEST PROCEDURE PERFORMANCE

- PROCEDURE PERFORMANCE DA TES COMPARED WITH HEAL TH PHYSICS AND SECURITY ENTRY LOGS

- ESTABLISHED ENTRY / EXIT TIMES FOR PERSONNEL

- IDENTIFIED ' COMMON DENOMINA TOR' 0F PERSONNEL INVOL VED

- A MAINTENANCE CRAFTSMAN INVOLVED WITH REMOVAL, REPLACEMENT AND TESTING OF VALVE IN PSV-1002 POSITION

- CRAFTSMAN STATED HE INSTALLED HYDROSET TEST DEVICE ON THE VAL VE IN PSV-1002 POSITION ,*

THE SAME PSV-1002 POSITION IN WHICH HE HAD PERFORMED THE VALVE REMOVAL AND REPLACEMENT

CONTINUING INVESTIGATION AND TESTING

ROOT CAUSE INVESTIGA TION PURPOSE o TO DETERMINE THE ROOT CAUSE OF THE FAILURE OF PSV .i002 TO LIFT AT THE DESIRED SETPOINT o TO VALIDATE THE TEST METHODS USED FOR BOTH IN-SITU AND OFF-SITE TESTING o TO IDENTIFY ACTIONS WHICH COULD BE TAKEN TO IMPROVE ANY NOTED PROBLEMS

ACTION PLAN o CONTRACTED OUTSIDE FIRM TO ASSIST IN THE INVESTI-GATION : 1HIS CONSULTANT HAS EXPERTISE IN THIS AREA BASED ON EXTENSIVE WORK FOR NAVAL REACTORS o OPENED A MORE INTENSE DIALOGUE WITH THE VALVE VENDORS CONCERNING DETAILED DATA AND APPLICABLE INDUSTRY DATA o PERFORM A DETAILED DIMENSIONAL AND VISUAL INSPECTION OF VAL VE REMOVED FROM PSV-1002 POSITION (Preliminary Inspection On-Site With the Vendor Revealed no Obvious Cause of the High Setpoint) o PERFORM A COLD SET PRESSURE TEST AND A HOT TEST OF VAL VE REMOVED FROM PSV-iOO2 POSITION o PERFORM ADDITIONAL DATA SEARCH OF APGL AND INDUSTRY FILES FOR SIMILAR OCCURRENCES o PERFORM A PIPING EVALUATION ON THE INSTALLED CONFIGURATION OF THE N0ZZLES ON BOTH UNITS WITH EMPHASIS ON CONTRIBUTIONS TO SETPOINT CHANGES

ACTION PLAN (Cont.) -

o PERFORM ADDITIONAL REVIEW OF APGL AND VENDOR PROCEDURES USED TO SET AND TEST THE VALVES

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FOR SIGNIFICANT DIFFERENCES OR IMPROVEMENTS FOR BOTH UNITS o PREPARE A DOCUMENTATION PACKAGE FOR REPLACEMENT VALVE (AS A CONTINGENCY) IF IT CANNOT BE CERTIFIED THAT VALVE WILL PERFORM SATISFACTORILY

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o PROVIDE SPECIFIC RECOMMENDATIONS BASED ON THE EVALUATIONS AND EXAMINATIONS RELATIVE TO PROCEDURES, TEST EQUIPMENT TRAINING, OR OTHER ASPECTS Note: These Tests and Inspections Will be Performed by a Contractor Other Than Those Previously used e

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CURRENT STATUS / PROJECTED SCHEDULE t JANUARY 27 -

ISSUE ACTION PLAN FOR ROOT CAUSE DETERMINATION FEBRUARY 7 -

CONTRACT A THIRD PARTY FOR ASSISTANCE FEBRUARY 15 -

ISSUE BID PACKAGE TO PURCHASING DE'ARTMENT FOR REPLACEMENT VAL VE MARCH 20 -

RECEIVED BIDS FOR REPLACEMENT VALVE FOR EVALUATION (CONTINGENT ACTION ONL Y)

APRIL 30 -

COMPLETE ANALYSIS OF ANO-1 AND ANO-2 PIPING CONFIGURATION JUL Y f -

BEGIN HOT FUNCTIONAL TEST (4 WEEKS)

AUGUST 28 -

ISSUE PRELIMINARY RECOMMENDA TIONS AND COMMENTS FOR DISCUSSION SEPTEMBER 20 -

ISSUE ROOT CAUSE INVESTIGA TION FINAL REPORT SEPTEMBER 30 -

PREPARE FOLLOW-UP LER RESPONSE

SAFETY SIGNIFICANCE OF POSTULATED VAL VE FAILURE

SAFETY SIGNIFICANCE OVERVIEW o TECHNICAL SPECIFICATION REQUIREMENTS o PSV PURPOSE o FSAR ANALYSIS o ANO-1 CYCLE-7 SPECIFIC ANALYSIS

ANO-1 TECHNICAL SPECIFICATION REGUIREMENTS o TECHNICAL SPECIFICATION 2.2.1 RCS PRESSURE SHALL NOT EXCEED 2750 PSIG o TECHNICAL SPECIFICATION 3.1.1.3 TWO VALVES REGUIRED FOR CRITICAL OPERATION ONE VALVE REGUIRED FOR SUBCRITICAL OPERATION o TECHNICAL SPECIFICATION BASES PREVENT OVER PRESSURIZATION OF THE REACTOR COOLANT SYSTEM

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ANO-1 PRESSURIZER CODE SAFETY VALVE o PURPOSE PWVENT OVER PRESSURIZATION OF THE MACTOR COOLANT SYSTEM (110% OF MSIGN PRESSUM) o ANO-1 SYSTEM LIFT PRESSUM 2500 PSIG o ASME RA TED FLOW 324, 000 lbm/hr

BGW OVEIPRESSURE PROTECTIM BOUNDING ANALYSIS o LIMITING EVENT CMTROL R00 WITH0RAWAL AT LOW POWER o BASIS TWO PRESSURIZER CODE SAFETY VALVES I -

2772 MWT POWER RATING (ANO-12568 MWT)

NO MODERATM AND DOPPLER FEEMACK COMPUTER C00E 'KAPPB'

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i MAXIMUM SYSTEM PRESSURE < 2700 PSIG MAXIMUM FLOW RELIEF < 50% OF BOTH PSV o CMCLUSION BOUNDING ANALYSIS WAS CMSERVATIVE l FW ANO-1 l

ANO-1 CYCLE 7 SMCIFIC ANALYSIS o BASED M CNE VALVE OPERABLE (324 000 LbWhr CAPACITY) 2568 MWT POWER RATING BOC MOMRATOR AND D00PLER CMFFICIENTS C0hPUTER CODE 'CADOS' '(NRC APPROVED) o LIMITING EVENTS CONTROL ROD WITHDRAWAL FROM LOW POWER o RESUL TS MAXIMUM PRESSURE < 2650 PSIG l

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l 0 BASED UPON THE CYCLE SWCIFIC ANALYSIS THE MACTM COOLANT SYSTEM WAS PROTECTED

FROM OVER PRESSURIZATION DURING CYCLE 7 DPERATION WITH THE POSSIBILITY OF ONE PMSSURIZER CODE SAFETY VALVE INOPERABLE 4

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CONCLUSIONS o FAILUM OF VALVE IN PSV-1002 POSITION TO LIFT l AT MOUIMD SETPOINT WAS FOUND AS A MSULT OF APGL INITIATED TESTING o ROOT CAUSE HAS NOT YET BEEN ESTABLISHED HOWEVER MVIEW TO DATE INDICA TES NO INCOR9ECT MAINTENANCE OR TESTING ACTIVITIES o APGL TOW PRUDENT ACTION TO REPLACE TM SUSPECT VALVE TO ALLOW FOR ADOITIONJL TESTING AND TO ASSURE VAL VE OPERABILITY '

o SUFFICIENT ASSURANCE EXIST THAT INSTALLED VALVES ARE OPERABLE o ROOT CAUSE EVALUA TION IS CONTINUING