Text

Rept of Investigation of Static O-Ring Differential Pressure Switches
	ML20207F525
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Site:	LaSalle
Issue date:	07/18/1986
From:	Abel J, Crane G, Davenport K; COMMONWEALTH EDISON CO.
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LASALLE STATION UNIT 2 REPORT OF INVESTIGATION OF STATIC "0" RING DIFFERENTIAL PRESSURE SWITCHES j

1 f Prepared by: J. S. Abel G. R. Crane K. E. Davenport L. H. Fitzpatrick R. L. Humphreys R. F. Janecek D. L. Rahn E. L. Seckinger E. E. Spitzner SARGENT8 LUNDY July 18, 1986 k

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COMMONWEALTH EDISON COMPANY "'g}4 x

LASALLE STATION UNIT 2 REPORT OF INVESTIGATION OF STATIC "0" RING DIFFERENTIAL PRESSURE SWITCHES O Prepared by: J. S. Abel G. R. Crane K. E. Davenport L. H. Fitzpatrick R. L. Humphreys R. F. Janecek D. L. Rahn E. L. Seckinger E. E. Spitzner i

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July 18, 1986 i

Document 40081

TABLE OF CONTENTS ,

g ~) PAG 3

\_s' SECTION TITLE I-l I.

SUMMARY

II-l II. INTRODUCTION III-l III. SOR DIFFERENTIAL SWITCH EVALUATION Discussion of Operation III-l A.

As Designed Off the Shelf III-l 1.

2. As Installed in LaSalle RPV Level Application III-l

3. As Installed in LaSalle Line Break Application III-l

4. As Installed in LaSalle Minimum Flow Applications III-2

5. As Calibrated in LaSalle Applications III-2 III-3 B. Calibration Methods IV. REACTOR LEVEL DROP TESTS IV-1 V. LASALLE SOR DIFFERENTIAL PRESSURE SWITCH SETPOINT CHARACTERIZATION PROGRAM V-1 A. Introduction V-1 B. Purpose V-3 C. Hypotheses V-4 s

1. Static Pressure Effect V-4

2. Cycling and Hysteresis Effects V-5

3. Time / Pressure Synergistic Effects V-6 D. Testing Procedures V-8

1. Static Pressure Test Rig V-8

2. Test 1 - Static Pressure Cycling V-8

3. Test 2 - Combined Static Pressure / Hysteresis Cycling V-9

4. Test 3 - Slow Approach to Setpoint V-10

5. Test 4 - Time-Related Effects V-10

6. Test 5 - Heavier Range Spring Force V-12

7. Long-Term Time-delated Tests by SOR V-12 E. Test Results V-16

1. General V-16

2. Reactor Water Level 3 Switches V-18

a. 2B21-N024A V-18

b. 2B21-N024B V-20

c. 2B21-N024C V-21

d. 2B21-N024D V-22

e. 2B21-NO38A V-23

f. 2B21-NO38B V-23

3. Testing of B203 Switch V-25

a. Spare B203 Serial Number 86-1-3269 V-25

b. Spare B203 Serial Number 86-1-3270 V-25 i

Document 40081

1 TABLE OF CONTiNTS (Cont.)

\. 4. Reactor Water Levels 2 and 1 Switches V-26

a. 2B21-NO31A, B, C, and D V-27

b. 2B21-NO37AB, BB, CB, and DB; 2B21-N026AB, BB, CB, and DB; and 2B21-NO37AA, BA, CA, and DA V-27 l

5. RHR/RCIC Steam Line and RHR Shutdown Cooling Line Break Detection Switches V-29

a. 2E31-N012AA, BA, AB, and BB; 2E31-N007AA, AB, BA, and BB; and 2E31-N013AA, BA, AB, and BB V-29

6. Main Steam Line Break Detection Switches V-30

7. ECCS Minimum Flow-Valve Control Switches V-31

8. Reactor Water Level 8 V-33

a. 2B21-N101B V-33 F. Evaluation of Static Variator and Procedure V-35

1. Differences Between Calibration and Static Variator Results V-35

2. Accuracy of the Test Measurement V-36

3. Rosemount Static Pressure Zero and Span Correction Factors V-37 VI. CORRELATION OF LEVEL DROP PERFORMANCE VERSUS OPERATIONAL / TIME TEST DATA VI-l A. Magnitude of Setpoint Shift VI-l O B. Level Drop Test 3 Versus Test 4 Behavior of VI-2 Switches VII. EVALUATION OF 2B21-NO38B (ADS) FAILURE VII-l A. Calibration History of 2B21-NO38B VII-l B. Switch Disassembly and Inspection VII-2 C. Switch Inspection at SOR's Facility VII-8

1. Spring-End Bearing VII-8

2. Switch-End Bearing VII-8

3. Cross Shaft VII-8

4. "O" Rings VII-9

5. Lower Spring Seat VII-9

6. Spring Retainer and Adjusting Cap VII-9

7. Adjustment Screw VII-9

8. Low-Pressure Body Bore VII-9

9. Spring VII-9 D. Summary of Conclusions VII-10 VIII. RECOMMENDED TESTING PROGRAM PRIOR TO OPERATION OF UNIT 2 VIII-1 IX. AMBIENT TEMPERATURE EFFECTS IX-1 l

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l Document 40081

TABLE OF CONTENTS (Cont.)

X. JUSTIFICATION FOR OPERATION OF LASALLE UNIT 2 X-1 A. General Electric Safety Parameter Range Analysis X-1

1. Overview X-1

2. Purpose X-1

3. Scope of Coverage for Analytical Limits X-2

a. Analytical Limits for Level X-2

b. Analytical Limits for Minimum Flow X-3

4. Results of Analytical Limits Evaluation X-3

a. Level and Minimum Flow X-3

b. High Energy Line Break Detection X-4

5. Conclusion X-4 B. Calibration. Procedure Revisions X-8

1. "First-Hit" ("As-Found") and "As-Left" Requirements X-8

a. Clarification of the Method Used to obtain the "As-Found" Setpoint for the Instrument X-8

b. Proper Setpoint Adjustment Techniques to Obtain the Most Accurate "As Left" Setpoint for the Instrument X-8

c. Cautions Against Overranging/Underranging the Switches During Calibration X-9

2. ' Static Pressure Offset Evaluation X-9

3. Revision of Setpoints X-9 C. Surveillance Revisions X-13 i 1. Frequency Required X-13

(( 2. Acceptance criteria X-13 X-13

a. New Switches

b. Existing Switches X-14 XI. WHY LASALLE IS CURRENTLY USING SOR SWITCHES XI-l A. History of Options That Were Available XI-l B. EQ Performance Test Results XI-6 C. Original Design Requirements XI-7 D. Evaluation of Generic Letter 84-23 XI-8

1. Background XI-8

2. Short-Term considerations XI-8

3. Long-Term Considerations XI-9

a. Replacement of Mechanical Level Switches with Analog Trip Units and Level Transmitters XI-9

b. Closure XI-10 l

1 iii Document 40081 I

_ _. -l

TABLE OF CONTENTS (Cont.)

APPENDIX A LIS-NB-201: Procedure for Low Water Level Scram Switches APPENDIX B Reference Material Provided by GPU Nuclear APPENDIX C SOR, Inc. Long-Term Test Plan APPENDIX D SOR Differential Pressure Switch Setpoint Characterization Test Data Graphs APPENDIX E SOR Differential Pressure Switch Setpoint Characterization Test Data Tables APPENDIX F Catalog Listing of Test Procedures APPENDIX G Response to Generic Letter 84-23 APPENDIX H SOR Report 8601-018: 103 Inspection of 6/26 and 6/27/86 (388) iv Document 40081

. _ . . _ _ _ _ _ _ . _ _ _ - - . _ . . _ _ _ ._ _ E _ _ _ . . _ _ _ _ - _ _ _ _ . . - _ - - -

LIST OF TABLES O' TABLE TITLE PAGE II-l List of Installed SOR DP Switches II-2 IV-1 Reactor Level Drop Test 1 Data IV-3 IV-2 Reactor Level Drop Test 2 Data IV-4 IV-3 Reactor Level Drop Test 3 Data IV-5 IV-4 Reactor Level Drop Test 4 Data IV-6 IV-5 Reactor Level Drop Test 5 Data IV-7 IV-6 Reactor Level Drop Test 6 Data IV-8 IV-7 Summary of Reactor Level Drop Test Data IV-9 IV-8 SOR Factory Performance Test Data Static Pressure Influence IV-10 IV-9 Elevation of Condensing Chambers IV-ll V-1 Calibration Data for the 2B21-N024 Switches V-7 V-2 Summary of Test Data Results for Reactor Water V-34 Level 3 V-3 Rosemount Conversion Factors for Span Corrections V-38 VIII-l SOR Differential Pressure Switch Test Program VIII-3 X-1 Analytical Limits on Level X-5 X-2 Peak Clad Temperatures X-6 X-3 Potential Ranges with Revised Analytical Limits X-7 X-4 Preliminary Acceptance Criteria X-15 XI-l Differential Pressure Switch Milestones XI-3 i

v Document 40081

LIST OF FIGURES l

v FIGURE PAGE TITLE I-l Reactor Water Levels I-3 l III-l " Apparent" Switch Performance on Successive Calibration Checks III-4 V-1 Static "O" Ring Differential Pressure Variator Test Setup V-13 V-2 Test 1: Static Pressure Effect V-14 V-3 Test 2: Cycling Effect at Elevated Static Pressure V-15 VII-l SOR, Inc. Differential Pressure Switch VII-4 and Assembly Drawing VII-5 VII-2 Differential Pressure Switch Internal Parts VII-6 VII-3 Cross Shaft VII-7 X-I Recommended Criteria for Selection of New Setpoints and for Acceptance / Rejection O Decisions During Surveillances X-12 i

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f vi Document 40081

I I. SUMi&RY BRAfl @

o On June 1, 1986, LaSalle County Station Unit 2 had a reactor feedwater system transient that caused reactor water level to drop below the setpoint of the low water level (level 3) reactor protection system i switches. This low water level " scram" function is initiated by four static "O" ring (SOR) differential pressure switches (manufactured by SOR, Inc.) that are calibrated to trip above the nominal Technical l

Specification setpoint of 12.5 inches above reactor instrument zero.

During the June 1,1986, water level transient, only one of these four level 3 switches tripped. (Figure I-l illustrates the relation between the different reactor water levels and the reactor water elevations.)

Following the observed anomalous operation of the level 3 switches, an investigation was initiated. An emphasis was placed on evaluating the unexpected variability of the level switch trip point. The initial phases of this investigation focused on reproducing the anomalous switch operation and evaluating potential causes. To reproduce the anomalous switch operation, tests were performed by actually lowering reactor water level through the setpoint of the level 3 switches.

These " level drop" tests reproduced similar anomalous switch operation to that observed during the June 1, 1986, reactor water level transient.

During these " level drop" tests, all four switches actuated, but three of the switches operated several inches below the Technical Specification allowable limit, which is 11 inches above reactor instrument zero, p Further investigations were conducted to identify specific cause(s) of the t anomalous operation. The level 3 switch piping, installation, and calibration procedure were reviewed.

On the basis of the initial findings, the cause of the anomalies was isolated to the unanticipated trip points of the SOR switches. No significant items were identified in the investigation of the instrument piping system, the switch installation, or the switch setting. For these four level 3 switches, data from factory performance tests, plant calibration tests, and the " level drop" tests indicated significant variation in switch trip points. From this initial investigation and from comparison of similar switch behavior at other plants, it was concluded that additional investigations would be necessary to adequately characterize the setpoint variability of the SOR switches.

At this point the investigation was expanded to include all models and safety-related applications of SOR differential pressure switches. For LaSalle Unit 2, this involved five different models and a total of 59 switches. The following portion of this summary applies to all LaSalle Unit 2 safety-related SOR differential pressure switches.

To adequately characterize SOR switch setpoint variability, special tests were performed on these differential pressure switches. These tests confirmed the variation in setpoint between calibration conditions and simulated operating conditions. These special tests showed setpoint variability similar to the reactor water " level drop" tests. These p special tests provided sufficient data to characterize the setpoint Q variability and provided the basis for developing revised switch calibration setpoints that ensure operation within Technical Specification limits. With the setpoint variability of the SOR switches adequately characterized and incorporated into the calibration procedures, it was concluded that these switches can be safely returned to service.

I-l DOCUMENT ID 39991/

To ensure the continued safe and reliable operation of these SOR differential pressure switches, instrument screening criteria were O established to reject or replace SOR switches on the basis of measured V static pressure offset. Also, improvements to the calibration technique and surveillance programs were recommended. In addition to the revised setpoints described in the preceding paragraph, the calibration procedures will be revised to clarify recording "as-found" and "as-left" setpoint data. The surveillance program will be revised to increase the surveillance frequency and to provide guidance for early detection of degrading switch performance.

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Reactor Water Lev;ls Figura 1-1 I

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.00 750 -

745- Vessel flan 9e Level 0 55.5 inches above instrument zero ACIC turbine trip HPCS engeClion valve Close 700 - Reactor feed pump trip Main turDine trip

% 40.5 inches above instrument sero H'gh-level alarm I 486 = Main steam line -

36.0 inches above instrument zero Normal reactor sevel

.00 -

- 587. g 31.5 inches above instrument tero

$33(g) 4 Low-level alarm C Recirculation flow runbacm permiss ve 568(7)

- 559(4)

$50 : Level 3 12.5 inches above instrument zero Bottom of steam - 540(3) dryer skirt Reactor scram 527.5 aname Instrument zero"" PCIS groups 6 and 7 ADS tow-level confirmation

/ Feedwater 500 -

493.25 p,c,rculation pumps transfer to sion spee:

-479.25- Core spray 477.5(2) - : Level 2 50.0 inches below instrument zero PCIS groups 1 2. 3 4 ano 5 450 -

HPCS enitiation HPCS d.esel generator starts ACIC initiation

- 416

! 400 - Recirculation pumps trip r Level 1 129.0 inches below instrument zero i -- 397.5(1) 377.5 Division 1 and 2 diesel gene'a' ors start 350

- 366 tpCS mitiation L PCI initiation ADS initiation 300 - - Level 0 211.5 4nches below instrument zero Two thirds core height Active fuel 250

=

216 200 j -181 Recire. discharge nozzle Recirc. suction 172.5 nozzle 150 -

100 50 Vessetaero

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6959. - Scale in 6nches above vessel aero.

07 86-39' I-3 DOCUMENT ID 39991/

II. INTRODUCTION (w

At about 4:20 a.m. on June 1, 1986, during a weekly surveillance on a Unit 2 turbine-driven reactor feed pump, the feedwater control system malfunctioned, causing Aarge fluctuations in the reactor water level. The reactor water level first increased to about 55 inches (above reactor instrument zero) and then dropped to about 6 inches before it returned to normal (36 inches).

Immediately prior to this transient, Unit 2 was operating at 95% power or about 1040 MWe.

Since the reactor water level dropped below the Technical Specification allowable limit of 11 inches, the reactor should have automatically shut down, or scrammed. However, only one of the four reactor protection system (RPS) level switches that initiate a scram actuated, and at least two of them must trip to initiate a scram. These level switches (instrument numbers 2B21-N024A, B, C, and D) are arranged in a "one out of two taken twice" logic and are normally set at 13.4 inches per the station's calibration procedures.

The level switches described above are SOR series 103 differential pressure (Dp) switches, model number 103AS-B212-NX-ClA-JJTTX6, with a range of 7 to 100 inches of water. These switches, along with 55 other SOR Dp switches, were installed during the spring 1985 outage to replace the originally installed Barton types 288A and 289A switches, which were not environmentally qualified for the entire 100-day post-1.OCA operating period. Table II-l lists the safety-related SOR DP switches installed on Unit 2.

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II-l DOCUMENT ID 39921/

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TABLE II-l LIST OF INSTALLED SOR DP SWITCHES h Taq Number Service Range Setpoint Model Number

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63.78" W.C. 103- B212 B21-N024A,B,C,D Rx. Level 3 7"-100" w.C.

B21-NO31A,B,C,D Rx, Level 2 20-200" W.C. 143.3" W.C. 103-B203 B21-NO37AB,BB Rx. Level 2 20-200" W.C. 145.5" W.C. 103-B203 CB,DB Rx. Level 2 20-200" W.C. 145.5" W.C. 103-8203 B21-NO37AA,BA Rx. Level 1 40-300" W.C. 200" W.C. 103-BB205 CA,DA Rx. Level 1 40-300" W.C. 200".W.C. 103-BB205 HPCS Min. Flow 5-35" W.C. 18.1" W.C. 103-BB202 E22-N006 E21-N004 LPCS Min. Flow 5-35" W.C. 11.01" W.C. 103-8202

.E12-N010AA RHR LPCI "A" Flow 5-35" W.C. 6.2" W.C. 103-B202 AB Alarm 5-35 W.C. 13.3" W.C. 103-B202 BA RHR LPCI "B" Flow 5-35" W.C. 6.2" W.C. 103-B202 BB Alarm 5-35" W.C. 13.3" W.C. 103-B202 CA RHR LPCI "C" Flow 5-35" W.C. 6.2" W.C. 103-B202 CB Alarm 5-35" W.C. 13.3" W.C. 103-8202

) Rx. Level 3 7-100" W.C. 63.14" W.C. 103-B212

[V B21-NO38A,B 20-200 W.C. 143.3" W.C. 103-BB203 B21-N026AB,BB Rx. Level 2 CB,DB Rx. Level 2 20-200 W.C. 143.3" W.C. 103-BB203 E31-N008A,B,C,D Main Steam Line Break 100-500 psid 111 psid 102-B305 E31-N009A,B,C,D Main Steam Line Break 100-500 psid 111 psid 102-B305 E31-N010A,B,C,D Main Steam Line Break 100-500 psid 111 psid 102-B305 E31-N0llA,B,C,D Main Steam Line Break 100-500 psid 111 psid 102- B305 E31-N012AA,BA RHR Shutdown Cooling 20-200" W.C. 170" W.C. 103-B203 E31-N012AB,BB RHR Shutdown Cooling 20-200" W.C. 170" W.C. 103- B203 E31-N007AA,AB RCIC Steam Hi Flow 20- 200" W.C. 117" w.C. 103-B203 E31-N007BA,BB RCIC Steam Hi Flow 20-200" W.C. 87" W.C. 103- B203 E31-N013AA,BA RCIC Steam Hi Flow 20-200" W.C. 170" W.C. 103- B203

/"'\

( ,) E31-N013AB,BB RCIC Steam 170" W.C. 103- B20 3 Hi Flow 20-200" W.C.

B21-N101B Rx. Level 8 7-100" W.C. 33.27" w.C. 103-B212 ,

II-2 f DOCUMENT ID 39921/

III. SOR DIFFERENTIAL SWITCH EVALUATION O

V A. DISCUSSION OF OPERATION

1. As Designed Off the Shelf The SOR differential pressure switches are diaphragm-operated mechanical-linkage-actuated microswitch switching devices. The diaphragm separates the high- and low-pressure chambers of the pressure retaining body. A compressed adjustable-range spring on one end of a rotating cross shaft normally has the microswitch switching element actuated against the microswitch spring on the other end.

When differential pressure is applied across the diaphragm and the pressure on the high-pressure side becomes greater than that on the low-pressure side by the amount of the preloaded adjustment spring, the diaphragm moves against the force of the adjustment spring, ~

compr'essing the spring more and deactuating the microswitch switching element. If the instrument is overranged, the diaphragm seats against the low pressure body and no damage will occur. If the applied pressure across the diaphragm is greater on the low-pressure side, no movement of the diaphragm will occur and physical protection is provided on the diaphragm assembly to prevent damage.

2. As Installed in LaSalle RPV Level Application These SOR differential pressure switches in normal service are continually subjected to approximately 1000 psig pressure on both sides of the diaphragm (static pressure). The high-pressure side of

(N

(_,) the diaphragm is connected through sensing lines to a condensate chamber off of the steam space of the reactor pressure vessel (RPV) to provide a constant pressure reference leg. The low-pressure side of the diaphragm is connected through sensing lines to the coolant region of the RPV to provide a variable pressure representative of the height of coolant above the RPV connection (variable leg). As RPV coolant level changes, the differential pressure across the diaphragm changes. When RPV coolant level decreases, the pressure on the low-pressure side decreases, analogous to increased pressure on the high-pressure side of the diaphragm, thus allowing the reference leg pressure to overcome the force of the range spring and deactuate the microswitch switching element. .

1

3. Fs Installed in LaSalle Line Break Application In service, these SOR differential pressure switches are continually subjected to approximately 1000 psig pressure on each side of the switch diaphragm. The high- and low-pressure sides are connected through sensing lines to a flow-sensing element (either a flow restrictor or an elbow). As steam flow varies normally, the element ,

in the steam line will vary the pressure on the diaphragm so that the l pressure is greater on the high-pressure side than on the low-pressure side. If a line break should occur, the element will rapidly cause the pressure on the high-pressure side of the diaphragm to increase to.at least double that for normal flow. This greater force on the high-pressure side of the diaphragm will overcome the s force of the range spring and deactuate the microswitch switching element.

DOCUMENT ID 39911 III-1

4. As Installed in LaSalle Minimum Flow Applications

(% In service, these SOR differential pressure switches are continually subjected to approximately 60 psig pressure on both sides of the diaphragm. The high- and low-pressure sides are connected through sensing lines to the upstream and downstream sides, respectively, of a flow element. When the ECCS pumps are initiated and flow established to the RpV, the pressure on the high-pressure side of the diaphragm becomes greater than u..t on the low-pressure side and that force overcomes the force of the range spring and deactuates the microswitch switching element, allowing the pump minimum flow valve l

to close. As normal ECCS flow is established, the differential pressure developed by the flow restrictor greatly exceeds the measurement range of these switches. If ECCS flow to the RPV is greatly reduced, the pressure on the high pressure side of the diaphragm is decreased until this force can no longer overcome the force of the range spring. The range spring force then actuates the microswitch switching element allowing the pump minimum flow valve to open.

5. As Calibrated in LaSalle Applications When the SOR differential pressure switches are calibrated, the pressure on each side of the diaphragm is simultaneously reduced to O psig, then the low-pressure side is vented to atmosphere. A calibration pressure source is then connected to the high-pressure

! side of the diaphragm and pressure increased to overcome the force of the range spring and deactuate the microswitch switching element. By (n) ', this method, the pressure on the high-pressure side of the switch is the setpoint. This pressure is then decreased and the compression of the adjustment spring changed as required to establish the desired setpoint. This adjustment process is repeated until the microswitch switching element deactuates at the specified instrument setpoint.

1 DOCUMENT ID 39911 III-2

B. CALIBRATION METHODS

() All SOR differential pressure switches are calibrated in accordance with applicable LaSalle instrument surveillance procedures, which require the following steps:

1. Isolate instrument, equalize (zero DP), and depressurize (zero static pressure);

2. Connect test equipment;

3. Cycle the switch;

4. Record "as-found" trip point and reset;

5. Adjust if required, record "as-left" setpcint, and reset;

6. Disconnect test equipment; and

7. Return to service.

i The switch behavior during calibration follows a recognizable pattern (see Figure III-1). When pressure is applied to the high side of the switch, starting from zero, the first actuation point is usually higher than the desired setpoint. Then, on successive cycling of the switch to its desired setpoint and reset point, the next few actuations are lower and lower. If the switch differential pressure is then reduced to zero again and pressure is applied in the vicinity of the desired setpoint, the next O, "first actuation" is usually found at, or very close to, the "first actuation" found in the previous series of cycling. Subsequent cycling of the switch repeats the pattern found in the first cycling.

After an incident in February 1986 when the automatic depressurization system SOR pressure switches failed to operate, the instrument mechanics were verbally instructed to cycle SOR pressure switches five times. All trips and resets were to be recorded.

The same instructions were later applied to SOR differential pressure switches when the station staff became aware of problems with SOR DP switches at the oyster Creek Station.

Due to the small amount of calibration history data and the different

methods of documenting the numerous cycles, no conclusions can be drawn l

concerning setpoint stability over time. Changes will be made to the

]

calibration procedures in order to better document setpoint history for the'SOR devices.

The desired setpoint for each SOR switch was determined by adding 1% of the instrument span to the nominal technical specification setpoint. In the case of the level 3 scram switches, the desired setpoint became 13.4 inches above instrument zero.

This report contains Appendix A, which is a copy of LIS-NB-201, the calibration procedure for the low water level scram switches.

(

DOCUMENT ID 39911 III-3

l l

Figure lit-1

" Apparent" Switch Performance on l

Successive Calibration Checks l

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1 I _ -

' Relatively First short time actuation "P8" Desired

-- - - - - trip point Ditterential ---

pressure 0 0 psig static pressure (normal calibration Check procedure) 0 Zero DA [

0DP (Same as Time ; valving switch back into service)

O C7-et-395 DOCUMENT ID 39911 III-4

IV. REACTOR LEVEL DROP TESTS DRAFTCOPY N Within 12 hours1.388889e-4 days 0.00333 hours 1.984127e-5 weeks 4.566e-6 months after the June 1, 1986 feedwater transient, the f calibrations of the four reactor protection system (RPS) level 3 switches were checked. The "as-found" setpoints varied between 65.5 and 64.1 inches of water column ("W.C.) differential pressure, which corresponds to ,

a reactor water level of 9.5 to 11.5 inches, respectively, above reactor l instrument zero. Although the setpoints were found out of tolerance, these data did not explain why these level switches did not initiate a scram during the transient when the level dropped briefly below 9.5 inches. Therefore, the decision was made to simulate the transient by performing reactor level drop tests. The purpose of these drop tests was to measure the response of these switches under normal operating conditions.

Six reactor water level drop tests were performed between June 2 and 5, 1986, in accordance with LaSalle test procedures LST 86-096 and 86-097.

Each test consisted of lowering the water level in the reactor vessel until all four level switches actuated. The tests were performed at reactor pressures of 950, 500, and 0 psig. Two level drop tests were performed at each pressure. A Gould recorder was used to monitor the output of each switch and the corresponding reactor water level. Since each switch is located at a different instrument rack, the level was monitored by four Rosemount differential pressure transmitters, one at each rack. As each switch tripped, the level reading at each rack was recorded. The calibration of the recorder and transmitters was checked before and after this series of tests, and the static pressure shift in q the span of one of the Rosemount transmitters was measured at 1000 psig in

[V ;

accordance with test procedure LST 86-125 and verified to meet Rosemount's specifications.

Upon completion of a level drop test, the reactor water level was usually increased to about 53 inches. However, between tests 3 and 4 the level only reached 36 inches, and between tests 4 and 5 the level was raised to 96 inches. Also, betweer the first and last level drop tests, the switches were not recalibrated or functionally checked except between tests 1 and 2.

The test results are shown in Tables IV-1 through IV-6 and summarized in Table IV-7. In the first six tables, the level readings are listed for each rack at the time each switch actuated. In Table IV-7 only the level indications at the same rack containing the level switch are listed. In each table the trip points for the switches are given both in reactor water level and in differential pressure that has been corrected for the Rosemount static pressure shift.

The test results show that the operation of the switches is affected by static pressure and that the level readings vary between the racks. Table IV-7 best illustrates the static pressure effect. Table IV-7 shows that the differential pressure setpoint of a switch increases as the static pressure increases, but that the amount of the increase varies from switch to switch. The average setpoint of these switches was about 3" W.C.

higher at 950 psig than at 0 psig. The variation in setpoints between the p j switches varied from 1" to 5" W.C. This observation is also supported by l V SOR's static pressure influence tests that were conducted on the switches

prior to shipping. These test results show that the setpoints on two of these switches increased by significant amounts as the static pressure was increased. SOR's test results are summarized in Table IV-8.

IV-1 7 i

l DOCUMENT ID 40021/

l Tables IV-1 through IV-6 illustrate how the level indications varied among g

the racks. The test results show that level readings ranged from 0.3" to 3.3" (0.2 to 2.4" W.C.) and that the differences between two racks remained fairly constant throughout a test. This variation is mainly due to the difference in the heights of the associated reference legs.

The elevations of the condensing chambers connected to the reference legs were measured and a 1.8-inch difference was found between the highest and lowest chambers. The results of this survey are summarized in Table IV-9. Af ter correcting the data to account for the condensing chamber elevations, the maximum difference between the racks was reduced from 2.4 to 1.4" W.C. (see Tables IV-1 through IV-6). In this analysis the readings from rack 2H22-P026 during test 2 were excluded because the transmitter failed during the next test and these data are questionable.

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TABLE IV-1

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. REACTOR LEVEL DROP TEST 1 DATA s ,/

A. Measured Trip Points in Reactor Water Level Trip Point (inches of water level above instrument zero) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 9.0* 8.7 6.3 5.7 2B21-N024C 9.3 9.0 6.9* 6.0 2B21-N024B 4.2 3.9* 1.5 0.9 2B21-N024D 12.9 12.6 10.5 10.2*

B. Trip Points in Differential Pressure

Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 66.l* 66.3 68.0 68.5 2B21-N024C 65.9 66.1 67.6* 68.3 2B21-N024B 69.5 69.7* 71.4 71.9 2B21-N024D 63.4 63.6 65.1 65.3*

C. Trip Points in Differential Pressure Corrected for the Condensing Chamber Elevations */5

[ Trip Point (inches W.C.) at Rack

\s Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 66.l* 66.3 65.2 66.7 2B21-N024C 65.9 65.1 65.8* 66.5 2B21-N024B 69.5 68.7* 69.6 70.1 2B21-N024D 63.4 62.6 63.3 63.5*

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Reading at same rack containing switch.

NOTES: ,

1. Date of test: June 2, 1986 i 2. Time of test: 1500 hours0.0174 days 0.417 hours 0.00248 weeks 5.7075e-4 months

3. Reactor pressure: 950 psig

4. Corrected for Rosemount static pressure shift.

5. Corrected with respect to rack 2H22-P004.

() 6. The switches were calibrated to trip at 63.1 to 63.4* W.C. prior to this test on June 1, 1986.

7. The transmitters used at each rack are listed in Table IV-9.

IV-3 DOCUMENT ID 40021/

-s TABLE IV-2

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~- REACTOR LEVEL DROP TEST 2 DATA A. Measured Trip Points in Reactor Water Level Trip Point (inches of water level above instrument zero) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026**

2B21-N024A 10.8* 10.5 9.0 5.1 2B21-N024C 10.8 10.5 8.9* 5.1 2B21-N024B 5.4 5.l* 3.0 0.6 2B21-N024D 13.2 12.6 11.1 8.4*

B. Trip Points in Differential Pressure

Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026**

2B21-N024A 64.9* 65.1 66.1 68.9 2B21-N024C 64.9 65.1 66.2* 68.9 2B21-N024B 68.7 68.9* 70.4 72.1 2B21-N024D 63.2 63.6 64.6 66.6*

C. Trip Points in Differential Pressure Corrected for the condensing Chamber Elevations */5

/]/

Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026**

2B21-N024A 64.9* 64.1 64.3 67.1 2B21-N024C 64.9 64.1 64.4* 67.1 2B21-N024B 68.7 67.9* 68.6 70.3 2B21-N024D 63.2 62.6 62.8 64.8*

Reading at same rack containing switch.

- The readings from the transmitter at this rack are questionable since the transmitter failed during the next test.

NOTES:

1. Date of test: June 2, 1986

2. Time of test: 2100 hours0.0243 days 0.583 hours 0.00347 weeks 7.9905e-4 months

3. Reactor pressure: 950 psig

4. Corrected for Rosemount static pressure shift.

5. Corrected with respect to rack 2H22-P004,

6. The switches were calibrated between tests 1 and 2 to trip at 63.1 to 63.3" W.C.

7. The maximum reactor water level between tests 1 and 2 was 56".

8. The transmitters used at each rack are listed in Table IV-9.

IV-4

TABLE IV-3

-# REACTOR LEVEL nROP TEST 3 DATA A. Measured Trip Points in Reactor Water Level Trip Point (inches of water level above instrument zero) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026**

2B21-N024A 9.6* 9.0 7.8 ---

2B21-N024C 10.2 9.6 8.4* ---

2B21-N024B 6.8 6.0* 4.8 ---

2B21-N024D 13.5 12.6 11.7 ---

B. Trip Points in Differential Pressure

Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026**

2B21-N024A 65.6* 66.0 66.8 ---

2B21-N024C 65.2 65.6 66.4* ---

2B21-N024B 67.6 68.l* 69.0 ---

2B21-N024D 62.8 63.5 64.1 ---

yg C. Trip Points in Differential Pressure Corrected for the Condensing Chamber

() Elevations */5 Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026**

2B21-N024A 65.6* 65.0 65.0 --

2B21-N024C 65.2 64.6 64.6* ---

2B21-N024B 67.6 67.1* 67.2 --

2B21-N024D 62.8 62.5 62.3 - - -

Reading at same rack containing switch.

- The transmitter at this rack failed during the test.

NOTES:

1. Date of test: June 3, 1986

2. Time of test: 1900 hours0.022 days 0.528 hours 0.00314 weeks 7.2295e-4 months

3. Reactor pressure: 500 psig

4. Corrected for Rosemount static pressure shift.

5. Corrected with respect to rack 2H22-P004.

6. The switches were not calibrated between tests 2 and 3.

7. The maximum reactor water level between tests 2 and 3 was 55".

8. The transmitters used at each rack are listed in Table IV-9.

IV-5

TABLE IV-4 O

(,-) REACTOR LEVEL DROP TEST 4 DATA A. Measured Trip Points in Reactor Water Level Trip Point (inches of water level above instrument zero) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 12.3* 12.0 10.8 9.3 2B21-N024C 13.1 12.5 11.4* 9.8 2B21-N024B 11.7 11.0* 9.9 8.3 2B21-N024D 13.8 13.4 12.0 10.5*

B. Trip Points in Differential Pressure

Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 63.7* 63.9 64.7 65.8 2B21-N024C 63.1 63.5 64.3* 65.4 2B21-N024B 64.1 64.6* 65.4 66.5 2B21-N024D 62.6 62.9 63.9 64.9*

C. Trip Points in Differential Pressure Corrected for the Condensing Chamber Elevations */5

['u.)h Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 63.7* 62.9 62.9 64.0 2B21-N024C 63.1 62.5 62.5* 63.6 2B21-N024B 64.1 63.6* 63.6 64.7 2B21-N024D 62.6 61.9 62.1 63.l*

Reading at same rack containing switch.

NOTES:

1. Date of test: June 3, 1986

2. Time of test: 2100 hours0.0243 days 0.583 hours 0.00347 weeks 7.9905e-4 months

3. Reactor pressure: 500 psig

4. Corrected for Rosemount static pressure shift.

5. Corrected with respect to rack 2H22-P004.

6. The switches yere not calibrated between tests 3 and 4,

7. The maximum reactor water level between tests 3 and 4 was 36".

8. The transmitters used at each rack are listed in Table IV-9.

IV-6 RREM!stR_R4_dRRRA/

TABLE IV-5 l

I x REACTOR LEVEL DROP TEST 5 DATA l

A. Measured Trip Points in Reactor Water Level Trip Point (inches of water level above instrument zero) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 i

2321-N024A 10.7* 9.5 8.7 8.1 2B21-N024C 12.9 12.0 11.4* 10.5 2B21-N024B 12.6 11.7* 10.8 10.2 2B21-N024D 14.3 13.1 12.2 11.6*

B. Trip Points in Differential Pressure

Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22- P026 2B21-N024A 64.7* 65.5 66.1 66.5 2B21-N024C 63.1 63.7 64.2* 64~.8 2B21-N024B 63.3 64.0* 64.6 65.0 2B21-N024D 62.1 63.0 63.6 64.0*

l C. Trip Point in Differential Pressure Corrected for the Condensing Chamber Elevations */5 Trip Point (inches W.C.) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 64.7* 64.5 64.3 64.7 2B21-N024C 63.1 62.7 62.4* 63.0 2B21-N024B 63.3 63.0* 62.8 63.2 2B21-N024D 62.1 62.0 61.8 62.2*

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Reading at same rack containing switch.

NOTES:

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1. Date of test: June 4, 1986

2. Time of test: 2100 hours0.0243 days 0.583 hours 0.00347 weeks 7.9905e-4 months

3. Reactor pressure: O psig

4. No static pressure correction required at 0 psig.

5. Corrected with respect to rack 2H22-P004.

l 6. The switches were not calibrated between tests 4 and 5.

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7. The maximum reactor water level between tests 4 and 5 was 96".

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8. The transmitters used at each rack are listed in Table IV-9.

V IV-7

TABLE IV-6

( REACTOR LEVEL DROP TEST 6 DATA A. Measured Trip Points in Reactor Water Level Trip Point (inches of water level above instrument zerc) at Rack Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 11.l* 10.5 10.1 9.8 2B21-N024C 13.2 12.3 12.2* 12.2 2B21-N024B 11.7 11.l* 10.7 10.5 2B21-N024D 14.7 14.1 13.6 13.5*

a B. Trip Point in Differential Pressure

Trip Point (inches W.C.) at Rack

. Switch No. 2H22-P004 2H22-P027 2H22-P005 2H22-P026 2B21-N024A 64.4* 64.8 65.1 65.3

! 2B21-N024C 62.9 63.5 63.6* 63.6 2B21-N024B 64.0 64.4* 64.7 64.8 2B21-N024D 61.8 62.3 62.6 62.7*

C. Trip Point in Differential Pressure Corrected for the Condensing Chamber Elevations */5 O Trip Point (inches W.C.) at Rack 2H22-P005 2H22-P026 Switch No. 2H22-P004 2H22-P027 2B21-N024A 64.4* 63.8 63.3 63.5 2B21-N024C 62.9 62.5 61.8* 61.8 2B21-N024B 64.0 63.4* 62.9 63.0 2B21-N024D 61.6 61.3 60.8 60.9*

Reading at same rack containing switch.

I NOTES:

1. Date of test: June 5, 1986

2. Time of test: 1400 hours0.0162 days 0.389 hours 0.00231 weeks 5.327e-4 months 1

3. Reactor pressure: O psig i

4. No static pressure correction required at 0 psig.

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5. Corrected with respect to rack 2H22-P004.

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6. The switches were not calibrated between tests 5 and 6.

( 7. The maximum reactor water level between tests 5 and 6 was 50".

8. Between tests 5 and 6 the reference and variable legs were backflushed.

9. The transmitters used at each rack are listed in Table IV-9.

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IV-8 rwauTTemL5tra_lYWhML______-___ __-__ _.

TABLE IV-7

SUMMARY

OF REACTOR LEVEL DROP TEST DATA A. Measured Trip Points in Rx. Level Test Rx. Pres. Trip Point (rx. level in inches)

No. Date Time (psiu) N024A NO24B NO24C N024D 1 6-2-86 1500 950 9.0 3.9 6.9 10.2 l 5.1 8.9 8.43 2 6-2 86 2100 950 10.8 3 6-3-86 1900 500 9.6 6.0 8.4 11.08 4 6-3-86 2100 500 12.3 11.0 11.4 10.5 l l 5 6-4-86 2100 0 10.7 11.7 11.4 11.6 6 6-5-86 1400 0 11.1 11.1 12.2 13.5 !

B. Corrected Trip Setpoints in Differential Pressure s Test Rx. Pres. Trip Point (inches W.C.)

No. Date Time _(psiq) NO24A NO24B NO24C NO24D 1 6-2-86 1500 950 66.1 69.7 67.6 65.3 2 6-2-86 2100 950 64.9 68.9 66.2 66.6 #

3 6-3-86 1900 500 65.6 68.1 66.4 64.68 4 6-3-86 2100 500 63.7 64.6 64.3 64.9 5 6-4-86 2100 0 64.7 64.0 64.2 64.0 6 6-5-86 1400 0 64.4 64.4 63.6 62.7 NOTES:

t

1. Corrected for the Rosemount static pressure shift.

2. These data are questionable because the transmitter or the rack failed during the next test.

3. Estimated value based on the level readings at the other racks and the elevations of the condensing chambers. The transmitter on this rack failed during the test.

4. The switches were calibrated to trip at 63.1 and 63.4" W.C. on June 1, 1986, between the feedwater transient and test 1. They were calibrated again ore 6-2-86 between tests 1 and 2 to trip at the same values.

5. Prior to tests 2, 3. and 6 the maximum reactor water level was 50 to 56" (37 to 33" W.C.). Between tests 3 and 4 the maximum reactor water level was 36" (47" W.C.), and between tests 4 and 5 the maximum reactor water level was 96" (4.b" W.C.).

6. Between tests 5 and 6 the reference and variable legs were backflushed.

L IV-9 mv_ ncs_jvnsa p_.

l TABLE IV-8 l l

SOR FACTORY PERFORMANCE TEST DATA DESCRIBING STATIC PRESSURE INFLUENCE l

Date of Setpoint (inches W.C.) at Switch EPN_ Test 0 psig 10 psig 350 psia 1375 osic !

2B21-N024A 2-5-85 12.5 12.6 12.7 12.8 2821-N024B 2-5-85 12.5 13.3 14.9 15.6 )

2821-N024C 2-5-85 12.5 14.7 15.7 17.3 ;

2B21-N024D 2-5-85 12.5 13.8 12.8 12.2 t

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IV-10 DOctJMENT ID 40021/

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TABLE IV-9

, ELEVATION OF CONDENSING CHAMBERS i

Condensing Level Instrument Level Elevation Chamber Switch Rack Transmitter (at centerline) Azimuth l

2821-N024A 2H22-P004 2C34-N004C 807' - 7.72" 340' 2B21-D004A 2H22-P027 2C34-N004B 807' - 8.72" 200*

1 2B21-D004B 2B21-N024B 1

2H22-P005 2C34-N004A 807' - 9.53" 160'

! 2B21-D004C 2B21-N024C

! 20'

! 2B21-D004D 2B21-N024D 2H22-P026 Test

807' - 9.47" a

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Temporarily installed on rack for test.

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. . ~ _ - . . _ -

I TABLE IV-8 SOR FACTORY PERFORMANCE TEST DATA DESCRIBING STATIC PRESSURE INFLUENCE Date of Setpoint (inches W.C.) at Switch EPN Test 0 psia 10_psig 350 psia 1375 psia 2B21-N024A 2-5-85 12.5 12.6 12.7 12.8 2B21-N024B 2-5-85 12.5 13.3 14.9 15.6 2B21-N024C 2-5-85 12.5 14.7 15.7 17.3 2B21-N024D 2-5-85 12.5 13.8 12.8 12.2 O

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J IV-10 nrerpRJM_(mW

DRAFT COM V. LASALLE SOR DIFFERENTIAL PRESSURE SVITCH SETPOINT d CHARACTERIZATION PROGRAM A. INTRODUCTION During the feedwater transient event at LaSalle County Station Unit 2 on June 1, 1986, it was noted that three out of four of the reactor water level 3 instruments required to initiate a level 3 scram at an indicated reactor water level of +11 inches apparently did not actuate at the desired setpoint. It was observed during subsequent testing that those three devices did actuate at lower reactor water levels, which indicates apparent large instrument setpoint variability. The magnitude of the variability was examined, and it was determined that the instruments themselves were the cause of this variability.

Subsequent testing of the four switches was conducted. The instruments were first monitored to determine their "as-found" condition using the station calibration check procedures. (Note: As described in Section III.A.5, the station calibration check procedure is done with the switches at zero static pressure.) It was noted that during this exercising, the switch setpoints were found to be in error; however, the magnitude of the error was determined to be much less than the apparent error during the feedwater transient event. It was postulated that the apparent instrument error might be due to a static-pressure effect, because the instruments are exposed'to a static pressure of approximately 1000 psig at normal operating conditions (as during the feedwater transient), whereas they are calibrated at ambient pressure per the station procedures.

U Additionally, the historical calibration data for these switches were examined to determine whether, in addition to a static pressure effect, there may be other effects that cause the instruments to drift (with time) from their original setpoints. The previous "as-found" and "as-left" data were compared to determine the magnitude and direction of the drift. It was noted that the majority of comparisons of the prior "as-left" to the next "as-found" conditions showed that the instrument setpoint appeared to have drifted toward a higher magnitude of differential pressure. This observation at LaSalle was consistent with a set of historical calibration data from the Oyster Creek Station (see Appenjix B).

The LaSalle Station staff also performed a reactor vessel level drop test in which the switches were exercised by raising and lowering reactor water levels while the RPV was at different elevated static pressures. (Refer to Section IV for data from this test.) The results of this test showed that one switch performed consistently poorly at elevated static pressures, but improved its performance with decreasing static pressures.

One switch performed better than all the others (but still showed a small error in switch actuation) at elevated static pressures and improved its performance at zero static pressure levels. Two switches responded similarly to one another (both better than the worst, but not as well as the best of the four switches). A comparison of these level drop test data with factory calibration data (submitted by SOR when the switches were fabricated) confirmed that the relative magnitudes of the instrumen.

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errors due to static pressure effect were consistent.

v-1 DOCUMENT ID 37251

b Based on the preceding observations it was decided to conduct an onsite

/N testing program to determine whether the magnitude and type of observed j

\~- errors in switch actuations were switch-unique or model-unique. It also was decided that a thorough testing program could be used to justify continued use of the SOR switches provided that the switch performance was 1

found to be predictable. For instance, once the magnitude of errort resulting from each effect were known for each switch, continued use of

' the SOR switches would be justified, provided that the magnitude and direction of error effects are predictable and fall within an acceptable 1

tolerance band, and the switches are adjusted accordingly. This would j result in a knowledgeable calibration of these instruments for the

! operating conditions.

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l V-2 a DOCUMENT ID 37251

_ _ _ _ _ _ _ . - . . . ~ _ _ _ , . ..__ - _ - . _ _ . _ . _ _

_ _ _ _ - . ~ , _ . _ . _ . _ _ _ _ _ _ _ . _ _ _ _ . . . _ _ _ _ - _ _ - _ . _

B. PURPOSE o The purpose of the testing described herein was three-fold:

l. To determine the magnitude of the static pressure effect on safety-related differential pressure switches (as manufactured by SOR, Inc.) that are installed or scheduled for installation at LaSalle county station. This magnitude was compared with an acceptance criteria to decide whether the switch should be used at LaSalle or whether it should be replaced with one having better l'

performance at elevated static pressures.

2. To measure the magnitude of the variance in setpoint due to exercise cycling of the switches to determine whether the setpoints encountered on successive exercise cycles are bounded by the "first actuation" encountered in the cycling. The knowledge gained from the test allowed conclusions to be drawn about the predicted performance of the switch once it has been calibrated and placed back in service. This expected performance is being factored into the determination of revised setpoints, allowable tolerance bands, and/or calibration procedures so that the next safety action requirement will be performed satisfactorily.

3. To determine the repeatability of performance of the SOR differential pressure (DP) switches on successive "first actuations," while maintaining the switch at an elevated static pressure over an extended period of time. If indeed there were a time-related O- phenomenon affecting the magnitude of the deviation from the setpoint, it was expected that a predictable performance of the SOR i

switches would be determined. These effects were documented, and recommendations for revised setpoints, allowable tolerance bands, and/or calibration procedure sequences and surveillance intervals are being made to take them into account.

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O V-3 DOCUMENT ID 372$1

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C. HYPOTHESES i From a review of the data collected following the apparent improper ,

i response of the reactor water level switches at LaSalle Unit 2 on June 1, 1986, it was postulated that the SOR differential pressure switches are j subject to the following effects:

. Static pressure effect, ;

! . Hysteresis effect - shift with overrange/underrange, and

. Time / pressure synergistic effects. ,

1. Static Pressure Effect l

The original SOR factory test data sheets for most of the subject

]

differential pressure switches supplied for LaSalle showed that there was some effect of static pressure upon the instrument setpoint.

Following the June 1 esent, LaSalle Station obtained six sets of data i through level drop ter.;s at 950 psig, 500 psig, and 0 psig reactor

]

pressure for four differential pressure switches 2821-N024A, 2B21-N0248, 2821-N024C, and 2B21-N024D (refer to Section IV).

The data obtained for three of the switches (A, B, and C) were consistent and in agreement with the original SOR test data in that i

the instruments' actuation point increased with an increase in static

l pressure.

j Switch B was the most susceptible to an increase in static pressure in the original SOR factory test data, as well as during the level drop test at LaSalle.

1 However, from the SOR factory test data, the D switch behaved such

' that on increasing static pressures the magnitude of the error remained approximately constant. Switch D had the smallest errot ;

I during the LaSalle level drop tests, i

j In general, all four switch performances improved (smaller and

! smaller error) when they were exercised at lower and lower reactor ,

pressures during the LaSalle level drop test. The D switch !

j consistently had the smallest error throughout the tests. The B switch consistently had the greatest error throughout the tests.

From this it was hypothesized that there in,a static pressure effect ,

, on these switches. It was also hypothesized that the magnitude of this effect varies from switch to switch of the same model number and ,

] range.

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DOCUMENT ID 37251

2. Cycling and Hysteresis Effects

,9 h From previous LaS&1le calibration data and from observations made by the instrument mechanics at LaSalle, it appeared that there was also both a " cycling" and a " hysteresis" effect.

The cycling effect can be described as follows:

On successive exercising of the switch during the calibration check procedure, the switch appears to actuate at lower and lower values, starting at a point higher than the desired trip setpoint, and approaching the setpoint on successive actuations.

The hysteresis effect is described as follows:

When the switch is first actuated by increasing the differential pressure (DP) across it starting from zero DP, the "first actuation" is higher than the desired trip setpoint. Then through successive cycling (exercising the switch such that the DP across it is increased and decreased only to the point of tripping and resetting the switch) the switch actuation approaches the desired setpoint. If the DP is decreased to zero again and the cycling is repeated, the next "first actuation" of the switch is very close to the "first actuation" previously observed.

However, if instead of reducing the DP to zero (as above), it is increased to 100% (or more) of the instrument adjustable range, the "first actuation" of the switch, when cycled, is a value lower than f')

'v the desired trip setpoint. Successive cycling of the switch (sets / resets) then shows an actuation point of higher and higher values approaching the desired setpoint.

An example of this effect is shown in the LaSalle Unit 2 March 31, 1986, calibration surveillance data for 2B21-N024A, B, C, and D (see Table V-1). The first six sets of data are the result of exercising the switch, having started from a zero DP condition. The seventh set of data for each switch was obtained by increasing the DP across the switch until 100% of adjustable range was reached, then lowering the DP until the switch reset point was reached, and finally increasing the DP again until the "first-actuation" point was reached again.

For all four switches, that "first-actuation" point was lower than the desired setpoint (whereas the "first-actuation" point reached when increasing the DP from a starting point of zero differential pressure showed an actuation point higher than the desired setpoint).

From the above observations, it was hypothesized that SoR DP switched exhibit a cycling a.id hysteresis effect. It was not possible t o conclude without further testing whether the magnitude of this efte t varied from switch-to-switch or from model-to-model.

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Y DOCUMt;NT ID 37251

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3. Time / Pressure Synergistic Effects It was not apparent from the level drop test data or the previous calibration nistory data whether time alone or elevated static pressure alone was enough to account for the magnitude of error in setpoint. It was hypothesized that both elevated static pressure and l elapsed time combine to account for much of the setpoint deviation error. In other words, "first-actuation" cycling after pressurization of the switch over varying amounts of time should be examined to determine whether time was indeed a factor in the error.

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DOCUMENT ID 37251

O TABLE V-1 O o CALIBRATI_0N DATA FOR THE 2821-N024 SWITCHES 2821-N024A I 2821-N0248 1 2821-N024C l 2821-N0240 I

As i. eft As found l As left l As Found l As left l As Found i As left Dat? of l As Found l l C*Iibration I Trip l Reset i Trip l Reset l Trip i Reset l Trip I Reset i Trip l Reset I Trip i Reset i Trip I Reset i Irip I Reset 4-6-85* lMA l NA l 63.2 l 58.8 l l l l l l l l l l l l 4-22-85* l l l l I NA l NA l 63.61 52.5 l l l l l l l l 5- M S* l I l l I l l l l NA l NA l 63.4 l 59.8 l l l l 5-16-85* I I I I I I I I I I I I I NA I NA I 63.4 1 58.6 r-5-85 I u.6 1 59.5 163.4157.5 I 67.0 1 55.5 l 63.0 1 51.8 I 64.6 I 58.6 1 63.0 1 57.2 1 64.8 1 58.6 I 63.4 1 58.0

! 1-3-86 1 63.9 I 59.0 163.3158.5 1 63.0 1 52.6 l 63.0 1 52.6 I 64.5 1 57.7 I 63.0 1 % .6 I 64.5 I 59.0 1 62.9 I 57.6 3-31-86 l 63.7 l 58.2 I l l 62.6 l 53.3 I l l 63.5 l 57.5 l l l 63.3 1 58.1 l l l 63.4 l 58.2 l l l 61.8 l 52.0 l l l 62.8 l 57.5 l l l 62.9 l 58.0 l l i I 63.1 l 58.4 l l l 61.5 1 52.5 l l l 62.6 l %.5 l l l 62.7 l 58.0 l l l 63.0 l 58.4 l l l 6i.5 l 52.5 l l l 62.7 I %.5 1 l l62.6l58.0 l l 1 63.1 l 58.4 l l l 61.4 l 52.6 l l l 62.7 l %.5 l 1 l 62.5 l 57.9 l l l 63.7 l 58.3 l l l 62.4 l 52.6 l l l 63.3 l 57.8 l l l 63.2 l 58.2 l l l 61.0 1 54.0 1 63.2 1 58.0 1 60.0 1 50.2 1 63.0 1 53.5 I 61.2 1 % .1 1 63.3 1 57.5 1 60.5 1 55.2 1 62.8 1 57.0 5-1 M l 64.6 l 58.5 l l l 63.1 l 54.1 l l l 64.4 l 58.8 l l l 62.8 l 57.0 l l l 63.3 1 58.4 l l l 62.8 1 54.0 l l l 63.8 l 58.8 l l l 62.2 1 57.9 l l l 63.2 l 58.5 l l l62.4l54.0 l l l 63.7 1 58.8 l l l 62.6 l 57.8 l l l 63.2 1 58.6 l l l 62.4 l 54.0 l l l 64.0 l 59.0 l l l62.4l57.6 l l 163.1158.6 I63.1158.6 1 63.2 1 54.0 1 63.2 1 54.0 1 64.0 1 58.9 I 63.1 I 57.8 I 62.4 1 57.7 I63.1158.4 6 1-86 l 65.5 1 58.3 l l l 64.8 1 54.6 l l l 64.1 l 57.4 l l l 64.6 l 58.6 l l l 64.6 l 58.4 l l l 63.8 l 54.5 l l l 63.1 l 57.8 l l l 63.9 l 58.7 l l 1 64.2 l 58.4 l l l 63.6 l 54.6 l l l 62.8 l 57.6 l l l 63.9 l 58.7 l l l 63.8 I 58.7 l l l 63.5 l 54.6 l l l 62.8 l 57.6 l l l 63.8 l 58.7 l l I 63.7 I 58.6 1 63.1 L58.1 1 63.6 1 54 6 163.i154.2 162.7157.7 1 63.3 I 57.5 1 63.a i 58.9 I 63.4 1 58.8 t

6-2-86 l 65.0 1 57.5 l l l 64.2 l 54.5 I l l 63.9 l 57.0 l l l 64.6 1 59.0 l l l 63.9 I 57.5 l l l 63.8 l 52.2 l l l 62.6 l 57.0 l l l 64.0 l 58.8 l l l 63.2 1 57.5 l l 1 61.9 l 53.0 l l l 62.4 l 57.0 l l l 63.8 l 57.8 l l l 63.2157.5 l l l 61.7 l 53.0 I l l 64.8 1 57.1 l l l 63.6 l 57.7 l l j 63.1 1 57.5 l 63.1 L57.5 161.61531 1 63.3 1 54.2 1 62.9 I 57.0 1 63.2 1 57.5 1 63.7 1 57.7 I63.1157.0

Initial Installation Date i V-7 j

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D. TESTING PROCEDURES

1. Static Pressure Test Riq At the time of the June 1 feedwater transient, LaSalle Station did not have equipment that allowed for the calibration of differential pressure instruments at elevated static pressures. Instead, the LaSalle Station Instrument Maintenance Staff had been using calibration procedures that are in widespread use throughout the power industry in the United States. These procedures provided for l

calibration and testing of DP instruments at zero static pressures.

In order to determine the magnitude of error in setpoint of an instrument at elevated static pressures, a special test rig was designed and built.

The test rig developed for LaSalle is as shown in Figure V-1.

1 Using this test rig, water was pressurized on both sides of the instrument and a measuring device simultaneously, while the differential pressure across the instrument was simulated by forcing a higher pressure on one side of the device while lowering the pressure on the other side of the device.

Switch contact actuation was monitored by placing a volt-ohm meter (set on the " ohms" scale) on the terminals of the switch and monitoring for centinuity or open-contact.

() Differential pressure applied to the instrument was monitored via a calibrated Rosemount transmitter. The transmitter was powered by a constant voltage power supply, and the load that the transmitter 4 drove was a precision resistor. The voltage across the resistor was monitored by a calibrated digital voltmeter.

In order to determine the predicted performance of each switch due to static pressure and cycling / hysteresis effects, the following testing was performed:

2. Lest 1--Static Pressure Cycling A static pressure effect cycling test was performed for all SOR DP switches (refer to Figure V-2). Each switch was first recalibrated per the regular station calibration procedure (LIS series) to put the unit into the existing instrument-allowable tolerance band (and known static pressure calibrated condition). Then each switch was cycled at zero static pressure (five cycles) and elevated static pressure (five cycles). Each set and reset was recorded. This test was repeated five times for each switch to determine the repeatability of performance of "first actuations." After many of the switches of each model/ range had been cycled and the "first actuation" trended, a smaller number of cycles was used to evaluate the remaining switches.

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Thi purpo30 of this tc t w:s to d2ternina tha magnituda of th2 error l encountered due to the static pressure effect. The results of the test were used to first select those installed switches considered to

/ be " good" performers with respect to minimal static pressure

\s_,}/ effects. Then the magnitude of the static pressure effect errors of the " good" switches was evaluated and used to help determine how the setpoint, allowable tolerance bands, and calibration procedures for these switches should be adjusted to obtain consistent acceptable performance.

Those switches deemed to be " bad" performers with respect to static pressure effects were to be replaced with " good" performers.

Switches that performed their safety actions on increasing DP were cycled at elevated static pressure starting from zero DP and exercised to record the set / reset points.

Switches that performed their safety actions on decreasing DP were cycled at elevated static pressure starting from both zero DP and 100% of the adjustable range.

The static pressures used for the test were the worst-case static pressures that would be seen by the DP switches when they are required to perform their safety actions.

All set / reset values were recorded.

During the test, the static pressure effect on the device used to measure the set / reset values was taken into account.

-- 3. Test 2--Combined Static Pressure / Hysteresis Cycling on a representative sampling of switches serving each plant function, a second test was conducted (see Figure V-3). This test was designed to determine the magnitude of the error introduced by the hysteresis effect. The switches were cycled (at their appropriate elevated static pressures) first starting from zero DP (10 cycles) and then starting from the switch's 100% adjustable range (10 cycles). This entire cycling was conducted twice for each switch tested.

By examining the data from both tests 1 and 2, it was evaluated whether the static pressure-effect error bounds, or is bounded by, the error from the cycling / hysteresis effects. The knowledge gained from these tests was used to evaluate a new repeatability performance band for each service function.

O V-9 DOCUMENT ID 37251

4. Test 3--Slow Approach to Setpoint For the switch that performed the worst on the level drop tests (2B21-N024B), a test was performed that evaluated whether the poor

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\,,, performance may have been due to the slow ramp rate at which the reactor water level was varied. (Note that the level drop test ramp rate was considerably slower than the ramp resulting in the feedwater transient.) The preceding tests described as test 1 and test 2 were repeated on this switch; however, the varying differential pressure applied to approach the setpoint and reset actuation was slowed to simulate the rate.used during the level drop tests. The ramp rate was specified in terms of millivolts of change in reading per unit of time.

5. Test 4--Time Related Effects The question of whether there is a relationship between the amount of time that a switch is subjected to an elevated static pressure and, the amount of static pressure effect error was examined by subjecting several switch units to elevated static pressure over varying amounts of time, and then cycling to determine the "first-actuation" point.

Successive "first-actuation" cycling following each time / pressure subjection was compared to determine whether the error continually increases with time, or whether the amount of incremental error due to pressurization tended to approach a maximum after a fixed amount of time.

The procedure was to bring the switches up to their operating static pressure and hold the pressure constant for periods of 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months , 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months , and 72 hours8.333333e-4 days 0.02 hours 1.190476e-4 weeks 2.7396e-5 months . The switches were then monitored as O' follows:

a. For the first switch: pressurize the switch for a period of 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months (test 4a). Monitor the "first-hit" actuation by increasing the differential pressure from zero and record the setpoint and reset point. Compare the first-hit found after 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months with that of no pre-pressurization.

perform test 1 and test 2 again on this switch following the 4-hour test to establish a baseline for comparison with the following test (test 4b).

pressurize the switch again, for a period of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . Agoirs.

monitor the "first-hit" actuation (test 4b-1). Compare the first-hit for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months with the first-hit for 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months to determine whether the first-hit differential pressure required to actuate is grealet than befote. Reptessutlee to the elevated static pressure on the switch for an additional period of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months (test 4b-2). Compare the first-hit found after the second 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months with that found after the first 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months to see whethet the first-hit is repeatable.

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b. For the second switch: parfora tGst 1 cnd tOat ' to ssttblish a baseline for performance of the switch following no pre pressurization (test 4c). Then pressurize the switch for a

(' period of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months (test 4d-1). Compare the first actuation

' setpoint after 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months of pressurization with that found in the baseline. Then, without depressurizing the switch to zero static pressure, maintain the pressure for another 24-hour period (test 4d-2); i.e, total pressurization is 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months .

Again, cycle the switch to determine the "first actuation" following the 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months of pressurization. Compare the "first l

actuation" following 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months to that of the 24-hour "first actuation."

Finally, while maintaining the elevated static pressure for a third 24-hour period (Test 4d-3), for a total of 72 hvurs of pressurization, repeat the cycling to obtain "first-actuation" data and compare these data with the 48-hour and 24-hour data to determine whether the static pressure shift error has increased or maintained the same approximate range of values.

If any of the above-described testing yields data that indicate a significant slope between data points for a particular switch application, then additional data points and/or increased sample size selections should be considered for that application.

c. For the third switch: perform test 1 and test 2 to establish a baseline for performance of the switch following no a pre pressurization (test 4e). Then pressurize the switch for a i period of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . Compare the "first-actuation" point after 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months with that found after no pre pressurization (test 4f-1).

Then, while maintaining the elevated static pressure on the switch, hold the pressure for a full 48-hour period without disturbing the switch (test 4f-2). Then, af ter the 48 hour5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months s have elapsed, compare the "first-actuation" setpoint with that found after only 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months of pressurization.

The purpose of this testing was to establish whether the 24-hour interval cycling to establish "first-actuation" in the previous time tests (in a. and b. above) has any effect on the magnitude l

of the setpoint error.

j d. For other switches: pressurize the switch for periods equal to

the period found (from the previous tests) to be most indicative of having produced the largest stabilized static pressure offset error. After that period has elapsed, cycle the switch to 1 deletmine its elevated mLalle pleanute error.

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6. Test 5--Heavier Range Sprino Forcs To evaluate whether a switch with a heavier range spring force (greater spring rate constant) has a markedly better performance when

( set at the desired setpoint for the reactor water level 3 switches, a B203 switch (used for reactor water level 2 and I settings) was set up on the static rig and tests 1 and 2 were performed. The switch was set for a 63.15" W.C. desired setpoint and monitored for performance during the testing to determine whether the switch setpoint is more repeatable.

7. Long-Term Time-Related Tests by SOR l As a means of confirming the test data gathered in'the LaSalle testing program, SOR Inc. was requested to perform a parallel test to be conducted over a much longer period of time. In their test program, they are exercising several different models <>f differential pressure switches at various intervals, ranging from every day for some switches, every 2 weeks for others, every 4 weeks for others, to every 6 weeks for still others. The purpose of their testing is to determine the magnitude and direction of the setpoint error over time. Details of their testing program are included in Appendix C.

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Static "O" Ring Differential Pressure Variator Figuro V-1 Test Setup O

To process I f1 F A k 4k M

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_J._ . Ohm T meter Sr>R switch under test O _

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Rosemount p /ro C so meter transmitter V V Pressure gauge X.

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-3 DOCUMENT ID 37251

Test 1: Static Pressure Effect Figure V 2 (Combined with Cycling) db First actuation First ectuation pressure ,

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etatic trip DP g a p ,,,, .'

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Notes: Test designed to determine magnitude of static pressure effect and differentiate " good from bad switches 1 and to monitor the relationship of static pressure effect with hysteresis effect to show correlation O

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Test 2: Cycling Effect at Elevated Static Pressure Figure V-3 O

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- - " " " - - - - " " " ~ - - - - - - - _ Onnange 100:: condition differential pressure First actuation g

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ea59 5 C'-EF-395 V-15 DOCUMENT ID 37251

E. TEST RESULTS

1. General The testing program hypotheses were first tested on a selective sampling basis to examine the nature of the static pressure shift and hysteresis / cycling shifts. Early testing (June 11 through June 23) was both exploratory (to examine which effects and which testing methods are most significant with respect te simulating real plant conditions) and measurements-oriented (to determine relative magnitudes of shifts in setpoint due to elevated static pressure and

~

hysteresis / cycling). Much emphasis was placed upon proving the test methodology and verifying the measurements techniques.

Since the static rig apparatus was new to the plant, an examination first had to be made regarding the differences in calibration measurement technique using the existing plant Wallace & Tiernan (W&T) apparatus and the new static pressure rig. It was determined that the static pressure rig more closely duplicates (but not exac'tly duplicates) the actual plant operation in that a solid water-filled system is used as it is in the instrument rack / piping assembly.

There was a significant (approximately 1.5" W.C.) difference in calibration method error when switching between the W&T and the static rig. That is, the last reading on the W&T apparatus (at 0.0 psig) when compared with the first reading (0.0 psig) with the static pressure rig was generally less by about 1.5" W.C. This calibration measurement error is also present when the W&T calibrator is used under normal surveillance procedures. That is, when the switches are placed into service after having been calibrated with the W&T (gj calibrator, there is some nominal error. Further discussion of this phenomenon appears in Section V.F.1.

The results of the early testing (June 11 through June 23) were not able to duplicate the magnitude of the setpoint shift found during the level drop tests. Starting on June 23, the testing program was modified to include time and static pressure synergistic effects. It was hypothesized that the elastomers inside the switch may need to be pressurized for a period of time (a " soaking" period) before the switches exhibit the magnitude of setpoint shift as seen on the level drop test.

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Several switch units were placed on the static pressure rig and held at elevated pressure for various amounts of time. Those time units gT were 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months , 12 hours1.388889e-4 days 0.00333 hours 1.984127e-5 weeks 4.566e-6 months , 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , and 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months . In addition, some

( ,,) switches were held under pressure for up to 72 hours8.333333e-4 days 0.02 hours 1.190476e-4 weeks 2.7396e-5 months , with in-between cycling to obtain "first-hit" readings at 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months , and 72 hours8.333333e-4 days 0.02 hours 1.190476e-4 weeks 2.7396e-5 months of elapsed time under pressure. This testing was done to be able to characterize the "first-hit" readings with respect to the shape of the soaking curves. For the switches tested, it was noted that the 48-hour and 72-hour setpoint error data points were not significantly different from the 24-hour setpoint errors. (The 72-hour setpoint error was actually less than the 48-hour data.) The 4-hour data point was considerably less than the 24-hour data point.

It can be inferred from the data that the soaking / stabilization time for the switch setpoint to reach its full error magnitude is somewhere between 4 and 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , and that the difference between 24 and 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months is insignificant. For a summary of all time-testing data, refer to Table V-2.

After the first units were tested to characterize the " soaking" phenomena, the remaining switches were sampled selectively to characterize the amount of setpoint shift found for each particular application and setpoint. That is, a sample of switches was chosen from reactor water level 3, reactor water level 2, reactor water level 1, main steam line break detection, other system line break detection, ECCS minimum flow valve control, and reactor water' level 8 trip applications. The number of samples chosen for each group was directly related to the relationship between the magnitude of shift observed from the time / pressure test for the initial switch chosen in

() each group, and the existing margin between desired setpoint and LCO.

For example, for the reactor water level 3 trip function, the amount of shif t with time for the 2B21-N024B switch was so large relative to the existing margin, that all reactor water level 3 switches were tested using a period of at least 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months .

For the reactor water level 2 and 1 switches, the existing margins between desired setpoint and LCO were proportionally greater, and a smaller number of switches were chosen to characterize the time / pressure shift for thuse groups.

For the ECCS minimum flow valve control switches, the setpoints were revised so conservatively with respect to their LCOs that only two of the eight switches were chosen to monitor shift over time. Testing !

for those two switches showed the static shift error to be well within the conservative margin chosen for the new setpoints.

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The basis of sample size selection for the main steam line break detection switches (16 total) was to test for time shift only as a

[\-T/ confirmatory measurement. That is, all of the main steam switches behaved so similarly during the static pressure / hysteresis tests that it was decided that two switches could characterize the entire group's performance with respect to " soaking" over time.

For the remainder of the other system line break detection switches, the existing setpoints were chosen so conservatively with respect to the safety analysis that only one switch was chosen to characterize the group's performance. The switch selected to be time-tested was the one with the lowest setpoint on the adjustab;e range of the switch model. This criterion was used because early testing of a spare B203 switch (which has an adjustable range of 20 to 200 inches) set at a setpoint of 63" W.C. exhibited more static shift error than another B203 switch set at 143" W.C., and this choice was considered to be the most conservative one.

The results of the testing described in the following sections are summarized in Appendixes D, E, and F. Appendix D contains a graphic depiction of the test results, and Appendix E contains the test data in tabular form. Appendix F is a catalog listing of each test procedure used for each test on each instrument. The completed procedures are on file in the records retrieval system at LaSalle County Station.

2. Reactor Water Level 3 Switches This level uses model B212 switches with a range of 7 to 100" W.C.

(

a. 2B21-N024A During initial testing with the static test rig (testing performed on switches 2B21-N024A and 2B21-N024B), the following two test anomalies were noted:

1) The static pressure test rig had leaked from the beginning of the test to the end of the test.

2) The calibrated Rosemount transmitter used as a standard to determine the differential pressure applied to the switch was found to have an unusual excess of both zero and span shifting from earlier measurements to later measurements during the test.

Both of these anomalies were corrected (the first by changing the "O" rings in the test rig and the second by using a new transmitter), and the testing was repeated. The results of the repeated testing are as follows:

O V-18 DOCUMENT ID 37251 l

Test 1--Static Pressure Effect. Switch 2B21-N024A was retested on June 19 and again on June 28 for operation at both zero and f 1000 psig static pressure. The June 28th test was run to try to

' confirm either the static pressure shift direction from the first (June 11) test with the bad Rosemount transmitter, or the June 19 test data. On the June 11 test, the switch setpoint had shifted at 1000 psig pressure to the nonconservative (higher l differential pressure) direction, as it had during the level j drop tests. On June 19, the test data indicated that the j switch setpoint had shifted toward the conservative (lower differential pressure) direction.

The retest on June 28 indicated that the static shift was to the nonconservative (higher differential pressure) direction. At best, from the above described performance, it can only be concluded that switch 2B21-N024A has exhibited a static shift in both directions. The magnitude of the shift toward the nonconservative direction did not exceed 2.5" W.C. throughout the testing, however. This.2.5" W.C. corresponds to a 3.5" reactor water level (RWL) shift.

Test 2--Hysteresis Effect. The effect of overranging the switch or underranging the switch can account for as much as a 5-inch shift in setpoint toward the conservative (lower differential pressure) direction. This value affects the normal operating margin but has no safety significance. The likelihood of overranging the reactor water level 3 switches without shutting down the plant is extremely remote. The instrument maintenance p procedures are very explicit with respect to valving these instruments back into service.

Test 4--Time / Static Pressure " Synergistic Effects. (Note: Test 3 was only performed on switch 2B21-N024B and found to yield an insignificant additional setpoint error).

Following the 24-hour time / static pressure soaking period, switch 2B21-N024A exhibited a nonconservative shift of 2.87" W.C. This amc,unt of shift would have allowed the switch setpoint to exceed the LCO. The switch setpoint had been calibrated and left at 63.1" W.C. (equivalent to 13.5" HWL) and at 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months of 1000 psig soaking had shifted to 66" W.C.

(equivalent to 9.4" RWL).

O V-19 DOCUMENT ID 37251

b. 2B21-N024B Since the "B" switch exhibited the largest static pressure error during the level drop tests, it underwent the most scrutiny in the LaSalle setpoint characterization testing program. First it had undergone tests 1 and 2 (using a bad Rosemount transmitter). Then the tests were repeated with a good transmitter. Finally, the "B" switch underwent a series of time / static pressure tests to try to characterize the shift with j l

applied static pressure over time.

I Test 1. The static pressure test indicated that the "B" switch l setpoint can exhibit a static pressure error of as much as 4.5" W.C. (6.4" RWL) in the nonconservative direction even before being subjected to pressure over a period of time. This value indicated that the switch would have exceeded the LCO (if set at the existing setpoint) by about 4" RWL.

Test 2. The hysteresis test showed that when switch "B" is overranged, it is capable of achieving a setpoint of 63.3" W.C.

(13.2" RUL) when set at 63.2" W.C. , which is conservative with respect to the LCO.

Test 3. It had been postulated that the level drop test was not representative of the actual feedwater transient in that the level drop test ramp rate was orders of magnitude slower than the June 1 feedwater transient event. It was decided that it

() may be prudent to try to simulate the level drop test by slowly approaching the trip point of switch "B" with the static pressure rig. Tests 1 and 2 were repeated with this test technique. The results of this test showed no additional shift. The instrument setpoint exhibited a slightly smaller shift (only 4.2" W.C.) with this approach than with test 1 at the normal ramp rate. However, the repeatability of the trip point was much worse than with the normal ramp rate.

Test 4. The switch was then subjected to its first-time dependency test, the first of which was for 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months . The switch was allowed to rest for several days at zero elevated static pressure. Then it was calibrated and left at 63.2" W.C. Next it was pressurized on the static rig and held at pressure for 4 hours4.62963e-5 days 0.00111 hours 6.613757e-6 weeks 1.522e-6 months . At the end of the 4-hour period, the first-actuation was found to be 67.0" W.C. (corresponding to 7.9" RWL). Next, the switch was allowed to relax and was recalibrated.

An operability test (tests 1 and 2) was repeated to establish a baseline for comparison for the following tests. The result was '

that the switch setpoint had shifted from 62.95" W.C. to 67.17" W.C.

O V-20 DOCUMENT ID 37251

The next test was a time / static pressure " soak" test for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . When the switch had completed this 24-hour soak, its

/~') setpoint had shifted from 63.2" W.C. to 69.2" W.C.,

k/

m corresponding to 4.8" RWL. This shift was very significant. l For the first time in the testing program, the testing started !

to yield static pressure shifts comparable to those found in the level drop tests.

As a confirmatory measurement, the "B" switch underwent a second 24-hour " soak" test, using elevated static pressure applied with the test rig. The switch setpoint shifted in this test from an "as-left" setting of 63.0" W.C. to 69.45" W.C., equivalent to 4.4" RWL. At this point, switch "B" was allowed to stay at elevated static pressure for another 24-hour period (48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months at elevated pressure, total). The 48-hour reading showed a 69.5" W.C. value, corresponding to 4.4" RWL, essentially the same value when taking intc account the limits of measurement accuracy.

Summarizing the time-test data for 2B21-N024B:

2nd 24 hour2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months /

4-hour test 1st 24-hour test 48-hour test "W.C./"RWL "W.C./"RWL "W.C./"RWL "As-Left" Setting 63.2/13.3 63.2/13.3 63.0/13.6 First-Actuation 67.0/7.9 69.2/4.8 69.45/4.4 48-hour First Actuation NA NA 69.53/4.4 O The above-listed time data for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months essentially duplicates the setpoint shift observed in the June 2 level drop tests.

c. 2B21-N024C Switch 2B21-N024C underwent a full operational test and time testing, similar to switches "A" and "B".

Test 1. The switch was cycled at both 0.0 psig and 1000 psig.

In this test, the switch was first calibrated with the W & T calibrator and set at 63.15" W.C. (corresponding to 13.4" RWL).

The first-actuation at zero static pressure was found to be 64.3" W.C. (11.8" RWL). The first actuation at 1000 psig was found to be 67.4" W.C. (7.4" RWL).

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l V-21 l DOCUMENT ID 37251

Test 2. The switch setpoint exhibited a shift of about 3" W.C.

when exercised after overranging.

O k- / Test 3. This test was not conducted for 2B21-N024C.

Test 4. Switch 2B21-N024C was cycled at 1000 psig; after having been set at 63.1" W.C. on July 6, 1986, and after having been held at 1000 psig pressure for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , it was found to exhibit a trip point at 68.3" W.C., which corresponds to 6.1" RWL. This shift was found to have been comparable to the shift exhibited on the level drop tests, as measured by the Rosemount transmitter mounted on the same instrument rack as 2B21-N024C.

d. 2B21-N024D The "D" switch had performed the best with respect to minimal static pressure error on the level drop test. It wss expected that testing would be able to daplicate this good performance.

The "D" switch was tested on June 29, 30, and July 1, which was late in the testing program, after the time-pressure dependency performance had been identified and confirmed through test data for other switches.

Test 1. A full static pressure performance test was conducted on June 29 to establish a baseline of performance. The switch was first calibrated and left at 63.2" W.C. The first actuation at 1000 psig was 64.5" W.C.

() Test 2. The hysteresis overrange cycling was able to produce a first-actuation trip point of 59.4" W.C. (18.7" RWL) again, this condition is almost impossible to achieve in normal operation.

Test 4. The "D" switch underwent a 24-hour soak, after having been calibrated and left at 63.5" W.C. The first actuation at 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months was 65.5" W.C., which corresponds to 10.1" RWL. This value very nearly duplicates the performance on the level drop tests. The "D" switch was then allowed to stay at an elevated static pressure for another 12-hour period. The first actuation at 36 hours4.166667e-4 days 0.01 hours 5.952381e-5 weeks 1.3698e-5 months was 65.9" W.C., corresponding to 9.5" RWL.

O V-22 DOCUMENT ID 37251

e. 2B21-NO38A

'~' Switches 2B21-N038A and B operate to provide a permissive function for the automatic depressurization system (ADS).

Switch 2B21-NO38A underwent testing on June 17 and June 1 through 4, 1986.

Test 1. The static pressure tests for switch 2B21-NO38A show that its trip point is subject to a static pressure influence of approximately 3.0" W.C. in the nonconservative direction (4.2" RWL) when immediately subjected to an elevated static pressure influence of 1000 psig. Multiple tests run at 1000 psig show very repeatable performance.

Test 2. The hysteresis test results show that switch 2B21-N038A exhibits a setpoint shift of approximately 3.8" W.C. As with the 2B21-N024A, B, C, and D switches, it is virtually impossible to overrange the instranent in normal operation without makin's a procedural valve realignment error.

Test 4. Switch 2B21-NO38A underwent a series of long-term time tests. The first such test was for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . The switch was calibrated and left at 63.3" W.C. (13.2" RWL) on July 1, 1986.

Twenty-four hours later, the first actuation was found to be 66.4" W.C. (8.8" RWL.) Next, the switch was allowed to relax i

back to atmospheric conditions for a period of 6 hours6.944444e-5 days 0.00167 hours 9.920635e-6 weeks 2.283e-6 months . The switch was repressurized to an elevated static pressure of 1000 psig. It was held at that pressure for a full 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months and left untouched during that period. Following the 48-hour " soak", the

['_ first-actuation point was found to be 66.7" W.C. (8.3" RWL).

f. 2B21-NO38B Switch 2B21-NO38B was suspected as not having actuated at all during the level drop tests. It is also suspected that this switch did not function during the feedwater transient on June 1, 1986 either. A work order to do a calibration surveillance test on the switch was executed in conjunction with the test program described herein. The surveillance revealed a "first-hit" trip point of 88" W.C. (corresponding to -21.8" RWL, which is below the effective normal operating measuring range for this switch). The switch was determined to be a failed device, and an investigation was launched to teardown and inspect the switch in detail. A full description of this inspection is contained in Section VII of this report.

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Test 1. It was attempted to test the switch for static pressure

'N influence and hysteresis cycling even though it was determined s

to have failed. This was done to determine whether the failure mechanism was significant enough to affect the static pressure phenomena or could be detected by performing tests such as tha LaSalle setpoint characterization program tests 1 or 2.

The results of the static pressure influence test showed a marked shift from desired setpoint, but not necessarily due to static pressure. The switch was first calibrated (with much I difficulty) and set to 63.4" W.C. (13.0" RWL). The switch was then cycled as though it were being put through test 1. The results of this test showed that the first-actuation point ranged from 69" to 72" W.C. (or 5.1" to 0.8" RWL). It also showed hardly any static pressure influence. The switch consistently performed poorly with respect to first-actuation points, and there was considerable scatter and mixture of data points taken at 1000 psig with data points taken at 0.0 psig.

Successive actuations of each cycle appeared to indicate some shift toward the nonconservative (higher differential pressure) direction at elevated static pressure; however, the first actuations for all the 1000 psig and 0 psig valves were well mixed among each other. The amount of deviation from desired setpoint averaged about 7" W.C. It was hypothesized that this offset was primarily due to friction inside the switch and not to static pressure influence.

() After test 1 on this switch but before the teardown and inspection, a calibration repeatability performance test was also run on 2B21-NO38B. For this test, the calibration was examined by turning the adjusting screw of the switch in equal turns both up from (lower setpoints) and down past (high setpoints) in 1/2 turns and full turns of the screw.

Repeatability of performance of trip function was examined as the switch adjusting screw was brought back to its starting i

point for each part of the cycle. The switch setpoint was found to be repeatable, however it was noted that for many portions of the turn of the adjusting screw, it was very difficult to turn.

l It was noted that a " grinding" feeling was transmitted from the' adjusting screw through the Allen wrench to the instrument mechanic's fingers. Also, it was noted that when slowly reapproaching the original setpoint from below the desired setpoint (i.e, when raising the setpoint by turning adjusting screw in minute increments to approach the desired setpoint), i f

the spring was often able to build up energy (compress) without yielding a higher setpoint. Then, after several minute turns of the adjusting screw had been expended, the next-actuation was found to be high all at once. A very repeatable setpoint was achievable, however, once the switch had been cycled about 50 ,

times.

O V-24 DOCUMENT ID 37251

I l

Switch 2B21-NO38B was not time-tested. Instead, it was replaced .

with a new switch with very good repeatability and low static f

(~'}

\ _s pressure offset performance (verified by test). ,

3. Testing of B203 Switch The LaSalle Station storeroom had two spare 103AS-B203 series l switches (20" to 200" W.C. adjustable range), which were tested with the static pressure rig for various lengths of time at a setting of 63" W.C. (the nominal setting for reactor water level 3 scram).

a. Spare B203 Serial Number 86-1-3269 Test 1. The spare switch serial number 86-1-3269 was tested to determine the static pressure effect. It was calibrated and left at 63.1" W.C. (13.5" RWL). It was cycled at 1000 psig and found to have a first-actuation point of 67.3" W.C.

(corresponding to 7.5" RWL).

Test 2. This test was not performed.

Test 3. This test was not performed.

Test 4. This switch was calibrated and left at 63.1" W.C. on June 25, 1986. It was allowed to sit at pressure (1000 psig) for a period of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . Then it was cycled to find its first-actuation point. It was found to trip at 68.5" W.C.

7-_ ,

(corresponding to 5.8" RWL). This switch at this setting (N- behaved similarly to the 2B21-N024B switch previously tested.

Next, the switch was allowed to stay at pressure (i.e., not brought down in applied static pressure) for an additional 24-hour period. The first actuation found after the switch had been pressurized for 48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months was 68.9" W.C. (corresponding to 5.2" RWL).

Finally, the switch was allowed to stay at elevated static pressure for another 24-hour period (72 hours8.333333e-4 days 0.02 hours 1.190476e-4 weeks 2.7396e-5 months total at 1000 psig). The switch was cycled and found to actuate at 68.7" W.C.

(corresponding to 5.5" RWL).

It was judged that this model switch (20- to 200-inch range) when set at the resctor water level 3 trip point, behaved very similarly to the B212 (7- to IPO-inch range) switch: The amount of static shift was aquivalent and the increase in setpoint after having been pressurized for a period of more than 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months was insignificant and within the limits of measurement.

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DOCUMENT ID 37251

b. Spare B203 Serial Number 86-1-3270

' Test 1. For the static pressure influence test, the switch was

__ set at 63.4" W.C. (13.0" RWL) and was found to activate (without long pressurization periods) at 65.7" W.C. (9.8" EWL). This j switch exhibited behavior similar to the 2B21-N024D switch )

described earlier. One interesting anomaly was noted: Once the ;

switch had been set at 63.4" W.C., its first-actuation points at both 0 and 1000 psig were always greater than the existing allowable tolerances for the B212 switches in the reactor water level 3 application. The 1000 psig cycles were nonconservative (ie., higher differential pressure) with respect to the 0-psig cycles; however, all the actuations were always greater than the existing instrument allowable tolerances provided for reactor water level 3.

Test 2, 3, and 4. These tests were not performed for the spare B203 switch serial number 86-1-3270.

4. Reactor Water Level 2 and 1 Switches These level applications used model B203, with a range of 20 to 200" W.C., and model B205 with a range of 40 to 300" W.C. Early test program procedures only covered tests for elevated static pressure and hysteresis cycling. Once the ef fect of time / static pressure was identified and verified by test for the B212 switches (essentially the reactor water level 3 switches) the reactor water level 2 and 1 switches were sampled for the same effect. All of these switches were first exercised and examined for static pressure effects. Those j

O- switches that appeared to exhibit the most nonconservative shift with respect to static pressure effects were then tested for time / pressure

" soaking" effects.

The switches chosen for examination of the time / pressure soaking effects were 2B21-NO31B, 2B21-NO31C, 2B21-N026CB, 2B21-N037AB, 2B21-NO37CB, 2B21-N037BA, and 2B21-NO37AA. The criteria used for inclusion of these switches in the sample were their relative magnitudes of nonconservative shift from tests 1 and 2 and the relative amounts of repeatability of performance at 1000 psig. Some switches were selected on the basis of excellent repeatability, and others were selected on the basis of poor repeatability performance.

Some switches were selected on the basis of large static shift as indicated on the previous data; others were selected on the basis of small static shift error.

Five of the switches chosen were to be representative of the 12 level 2 switches, and two of the switches were chosen to be representative of the four level 1 switches. The results of the testing were as follows:

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V-26 DOCUMENT ID 37251

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a. 2B21-NO31A, B, C, and D Test 1. These switches were first cycled to obtain confirmation (j"'N s

of the static shift phenomena (without time applied as a factor). The "A", "C", and "D" switches all performed within

, the existing instrument allowable tolerances.

The "B" switch behaved fairly repeatably during these tests; however, it exhibited slight static shift error in the nonconservative direction.

4 Test 2. All four switches exhibited approximately 2-1/2 inches )

of conservative shift when overranged. (It is highly unlikely, 1 2

! however, that these switches would ever experience an overrange condition and then have to perform their safety function).

Test 3. This test was not performed for the level 2 and I switches.

Test 4. This test was conducted on five leve? 2 switches and two level 4 switches. Two of the five level 2 switches tested were 2B21-NO31B and 2B21-NO31C.

2B21-NO31B was set at 143" W.C. on June 30, 1986. It was pressurized to 1000 psig and held at pressure for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . It was cycled at 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . Then, without depressurizing the unit to 0.0 psig, the switch was allowed to remain at pressure for an additional 24-hour period (48 hours5.555556e-4 days 0.0133 hours 7.936508e-5 weeks 1.8264e-5 months total). The first-actuation

occurred at 149.4" W.C. (a 6" W.C. shift in the nonconservative direction, corresponding to -55.3" RWL). This switch setpoint would not have exceeded the LCO of -57" W.C.

I I

Switch 2B21-N031C was set at 143.2" W.C. on July 3, 1986. On July 4, the switch was cycled after having been pressuriz'd e for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months at 1000 psig and found to have a first-actuation of 146.6" W.C., corresponding to -51.3" RWL. The "C" switch acted l more conservatively than the "B" switch.

b. 2B21-NO37AB, BB, CB, and DB: 2B21-N026AP, BB, CB, and DB; and I 2B21-NO37AA, BA, CA, and DA j

All the above-named switches are installed to provide the ECCS initiations at reactor water levels 2 and 1, corresponding to j -50" RWL and -129" RWL respectively. The level 2 switches

? (2B21-NO37AB, BB, CB, and DB; 2B21-N026AB, BB, CB, and DB) are d all model 203, with an adjustable setpoint range of 20 to 200" W.C.

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V-27 DOCUMENT ID 37251 i

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

Switches 2B21-N026AB, BB, CB, and DB are also provided with

' double-microswitch assemblies (code "BB") to fulfill the trip g_) functions required by the ECCS system design; all other level 2 switches have only a single microswitch. The level 1 switches (2B21-NO37AA, BA, CA and DA) all have double microswitches and an adjustable range of 40 to 300" W.C.

Tests 1 and 2. The level 2 and I switches were cycled at 0 and 1000 psig to determine their static shift and hysteresis effects when subjected to just static pressure (not time / pressure synergistic effects).

In general, all the switches behaved alike. In most cases, the pattern observed was that, when comparing the cycling at zero pressure to that at 1000 psig, there was a slight static pressure shift, mostly in the conservative (lower differenteial pressure) direction when the pressure nas first applied.

Within that group of switches there were a few switch trip points that exhibited a somewhat larger variance than others, dnd these switches underwent a further scrutiny. Switches 2B21-NO37BB and 2B21-N026CB, for instance, had cycling shifts at zero pressure of much greater variance than the other switches, and therefore, were more closely examined. The zero pressure variance indicated something other than just friction or hysteresis / cycling phenomena. The high repeatability of switch 2B21-NO37BB at 1000 psig on the June 16, 1986 test, coupled with

() the low repeatability of this switch at zero static pressure

\m/ seemed to indicate air-entrainment in the body of the switch (or some phenomenon creating similar results). This switch was vented, zeroed, recalibrated, and tested again on July 1, 1986, and was found to exhibit a much more repeatable performance at both 0 and 1000 psig static pressures.

All switches were tested for their performance at 1000 psig following overranging and underranging. In general, they all exhibited a shift of 2 to 3" W.C. after having been overranged.

Test 4. As described above, seven switches were chosen to be tested as representative of the twelve level 2 switches, and four level 1 switches. The basis for selecting the seven switches is described above. The results of the testing yielded the following:

O V-28 DOCUMENT ID 37251

l (NOTE: the results of the time tests for switches 2B21-NO31B and 2B21-NO31C are described above). j Switch Tag No.

Reactor Water Level 2 Reactor Water Level 1 ,

I 2B21-NO37AB 2B21-N037CB 2B21-N026CB l 2B21-NO37AA 2B21-N307BA "W.C./"RWL "W.C./"RWL "W.C./"RWL l "W.C./"RWL "W.C./"RWL l l

"As-Left" 142.2/-45.2 142.2/-45.2 143.9/-47.6 l 199.5/-125.3 199.5/-125.3 Calibration l l

First Actua- 146.6/-51.4 145.8/-50.2 146.7/-51.5 l 202.3/-129.2 206.4/134.9 tion after 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months l l

1

5. RHR/RCIC Steam Line and RHR Shutdown Cooling Line Break Detection Switches These applications use the B203 (20 to 200" W.C.) adjustable range. The switches are required to detect a line break (i.e., abnormally high steam or water flow sensed) in terms of a high percentage of process line flow.

For instance, the setpoints chosen for detection of line breaks in terms of differential pressure are defined in terms of the differential pressure corresponding to 127% of rated flow for most of these lines,

a. 2E31-N012AA, BA, AB, and BB: 2E31-N007AA, AB, BA, and BB: and 2E31-N013AA, BA, AB, and BB Test 1. These switches were cycled at 0 and 1000 psig elevated static pressure. For the most part, the cycling exhibited a slight (1.5 to 2.0" W.C.) static shift error in the nonconservative direction. In all cases, the cycling yielded trip points of the switches within their existing instrument allowable tolerance bands.

Test 2. Since these switches operate to detect a gross increase in flow, indicative of failure of the pipe, they were not tested to find their operability after having been overranged.

Test 3. This test was also not performed on these switches.

Test 4. Because tests 1 and 2 showed excellent repeatable performance for every switch in this group of switches, it was decided to do a time / pressure synergistic effects performance on only ,

one switch as a representative of the group. Test 4 was performed on switch 2E31-N007BA. The switch was calibrated and set at 87.5" W.C.

on July 5, 1986. On July 6, the switch was cycled after having been pressurized at 1000 psig for a period of 25.5 hours5.787037e-5 days 0.00139 hours 8.267196e-6 weeks 1.9025e-6 months . The first actuation occurred at a differential pressure of 80.6" W.C. , which h indicative of a static shift in the conservative direction.

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DOCUMENT ID 37251

4 - - . m >

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6. Main Steam Line Break Detection Switches There are 16 switches in this group (four on each main steam line). Each switch is a SOR Model 102AS-B305 series switch. They differ from the 103 series switches in that they use a piston rather than a diaphragm for the differential pressure sensing mechanism. They are set to detect a differential pressure that corresponds to approximately 133% of the main steam line maximum operating flow. They have an adjustable range of 100 to 500 psid, and they are set at 108.5 psid. (The Tech Spec allowable value is 116 psid.)

Test 1. All the switches were tested for their operability at 0 and 1000 '

psig elevated static pressure. All switches performed consistently, with a high degree of repeatability at both 0 and 1000 psig elevated static pressure. Switches E31-N008B and E31-N011C were chosen to have time tests performed on the basis that E31-N0 llc was the most repeatable at both I

pressures, and E31-N008B was the least repeatable. In addition, switch E31-N008D exhibited a larger variance in trip points at both 0 and 1000 psig than the others, so it was selected to undergo time testing also.

Test 2. All the swltches tested exhibited a 1-to-2-psid trip point shift In the conservative (lower psid) direction after having been overranged.

This condition is not likely to occur in normal operating or accident conditions, f' Test 3. This test was not performed on the main steam line break detection switches.

Test 4. Switches 2E31-N008B, 2E31-N008D, 2E31-N0llA, and 2E31-N0 llc were selected (on the basis of their variance in performance on test 1) as i representative of the 16 main steam line break detection switches. They

! were selected as performing the least conservatively on the static pressure test (with the exception of switch 2E31-N0 llc, which performed the most repeatably).

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I The switches performed as follows, after having been pressurized to 1000

/""'

psig, held at pressure for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , and then cycled to obtain first

(,,) actuation trip points:

Switch Tao No.

2E31-N008B 2E31-N008D* 2E31-N0llA* 2E31-N011C Differential Differential Differential Differential Pressure Pressure pressure Pressure (psid) (psid) (psid) (psid)

As-Left 107.5 setting 108.0 109.4 108.5 First Actuation 113.0 after 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months 118.0 116.0 116.5

Since the performance of switch 2E31-N008B showed a static shift error of 10 psid (2.5% of adjustable range), it was recommended that switches 2E31-N008D and 2E31-N011A be tested also, on the basis of their larger variance on test 1.

7. ECCS Minimum Flow Valve Control Switches These minimum flow applications make use of the SOR Model 103AS-B202 series switches, which have an adjustable setpoint range of 5 to 35" W.C.

The switches are required to be able to detect a decreasing ECCS injection flow and, upon detection of a pre-set flow rate, open up a minimum flow

\-- valve, which helps to protect the ECCS pump from destroying its impellers because of low flow.

Traditionally at LaSalle, these switches have exhibited problems in achieving the minimum flow requirement, because the number of inches of water column that corresponds to the minimum flow rate required for the safety action is low in comparison with the switches' minimum adjustable range. Operability tests were conducted for these switches. However, in the operability test, several switches were required to function below their minimum adjustable range. The operability test data were therefore not plotted.

Instead, the available margin above the required minimum flow was evaluated to determine whether it would be prudent to raise the setpoint to a value that would ensure opening of the minimum flow valve well before it was required. This was done on the basis that the analysis performed by the General Electric Company (see Section X.A) showed that there is no real requirement for the ECCS systems, once initiated, even to close the minimum flow valves.

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V-31 l DOCUMENT ID 37251

Therefore, the setpoints for all the ECCS minimum flow valve control switches were raised to slightly higher than the middle of the switch's adjustable range. The changes were as follows:

System / Switch Old Setpoints New Setpoints

" W.C./gpm " W.C./gpm LPCS Valve Control /2E21-N004 11.0/1189 23.0/1719 HPCS Valve Control /2E22-N006 10.0/1015 23.0/1540 LPCI-A Valve Control /2E12-N010AA 6.2/1026 23.0/1977

LPCI-A Alara/2E12-N010AB 6.2/1026 23.0/1977 LPCI-B Valve Control /2E12-N010BA 6.2/1026 23.0/1977 LPCI-B Alarm /2E12-N010BB 6.2/1026 23.0/1977 l 6.2/1026 23.0/1977 i

LPCI-C Valve Control /2E12-N010CA LPCI-C Alarm /2E12-N010CB 6.2/1026 23.0/1977 finally, as a confirmatory test to verify that all the minimum flow valves do indeed open when required, a system operability test was run for each l

ECCS loop. Each system flow was monitored while the valve limit switches and differential pressure switch were monitored. Each switch performed

! its safety function with a wide margin. For instance, the lowest flow reached among the many trials for each switch were as follows:

i System Operability Test Results Nominal Tech Tested Trip Tested Trip l

System / Switch Spec Ream't (Open) Point (Open) Point (Closed) l () (gpm) (gpm) l (9Pm)

LPCS Valve I Control /2E21-N004 640 1414 2150 HPCS Valve

l. Control /2E22-N006 900 1296 1960 !

LPCI A Valve i Control /2E12-N010AA 550 1785 2277 LPCI B Valve

! Control /2E12-N010BA 550 1658 2179 LPCI C Valve

! Control /2E12-N010CA 550 1695 2398 J

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. _ . _ _ - . . - . - . . I

8. Rxactor Water Ltval 8 ,

One of the four switches that provide a trip function to the HPCS and RCIC pumps when high level in the reactor vessel is reached is a static "0"

(~N ring model 103AS-B212. This switch h'as an adjustable range of 7 to 100"

\_,) W.C. It was tested as part of the LaSalle Setpoint Characterization Test Program. ,

a. 2B21-N101B Tests 1 and 2. The switch was cycled at zero and 1000 psig static pressures (two cycles, each pressure) to obtain 5 set / reset values.

The switch was found to exhibit a nonconservative (lower differential Pressure) static shift error of approximately 1.25" W.C. (1.8" RWL). '

This test was conducted starting from the overrange condition (normal operating condition for this switch) to combine the effect with the test 2 procedure.

Test 3. This test was not conducted on 2B21-N101B.

This switch was calibrated and set at 34.7" w.C., I Test 4.

corresponding to 53.7" RWL. It was held at elevated static pressure for 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . At the end of the period, its trip point was found to have shifted to 31.3" W.C. (+58.16" RWL).

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O V-33 DOCUMENT ID 37251

CJ O, /u~N IABLE v!2 SUMARY OF TEST DATA RESUtis FOR REACIOR WATER LEVEL _3 i

l 2821-N024A l 2821-N0248 l 2821-N024C l 2821-N02_40_ l,2821-NO3BA l 2821-NO388 l("W.C./"RWL) l (N.C . /"RWL ) l("W.C./"RWL) l("W.C./"RWL) l("W.C./"RWL) l (N.C./*RWL)

! "As left" Setpoint (W.T.) l 63.3/13.2 l 63.0/13.2 l 63.1/13.4 l 63.2/13.3 l 63.1/13.5 l 63.4/13.0 I I I I I I I I I l l l 0.0 psig First-Hit l 64.72/11.2 l 64.1*/12.0 l 64.3/11.8 l 64.8*/11.0 l 64.810/11.1 l 70.C' */2.6 (static rig) l l l l l 1 l l 1 l l 1000 psig First-Hit l 66.12/9.2 l 67.2*/7.7 l 67.4/7.4 l64.7*/11.2 l 66.11/9.2 l 72.01*/0.9 (static rig) l l l l l l 1 1 1 I i l l

! 1000 psig First-Hit l 66.02/9.4 l 69.25/4.8 l 68.3/6.1 l 65.6'/9.8 l 66.4/8.811 l NA / NA (24 hr-static rig) l l l l l l l l l l l l 1000 psig First-Hit l NA / NA l 69.4*/4.4 l NA / NA l NA / NA l N/A / N/A l NA / NA (2nd 24 Hr. Static Rig) l l l l l l l l l l l l 1000 psig First-Hit (48-hr l NA / NA l 69.5/4.41' l NA / NA l NA / NA l66.7/8.3" l NA / NA static rig l l l l l l Notes: 1. timits of error in measurement: "W.C. at Switch in test rig data - Value 1 0.699" W.C. (2a error in measurement loop)

" Reactor Water level in Vessel = Value 1 0.99" RWL

2. Data f rom " mini-operational" test for 2821-N024A.

3. Data from 24-hour test data for 2821-N024A.

4. Data f roen baseline test between 4-hour and 24-hour test data on 2821-N0248.

5. Data f rom first 24-hour test on 2821-N0248.

6. Data from second 24-hour test on 2821-N0248 (note that pressure was reduced to zero between 24-hour tests 1 and 2).

7. Switch 2821-N024C is on hold from testing (NRC hold point).

8. Data f rom operational test of 2821-N0240.

9. Data from 24-hour test of 2821-N0240.

10. Data f rom original fu11 operational test of ?821-NO3RA and 8.

11, Data from time testing of 2821-NO3BA.

12. NO48R was found to be a failed switch.

13. Switch was cycled at 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months to check trip / reset, but remained at 1000 psig static pressure.

V-34

F. EVALUATION OF STATIC VMtIATOR AND PROCEDURE

1. Differences Between Calibration and Static Variator Results Use of the static variator at atmospheric pressure to check the SOR trip points resulted in an apparent upward setpoint shift of 1.5 to 2" W.C. from the values obtained using standard calibration devices. part of this shift is attributable to the method used to obtain "as-left" setpoints during calibration.

The "as-left" value is taken after several repeatable cycles of j the switch while cycling around the trip and reset values. Test data on the switches demonstrated that a value obtained this way is approximately 1" W.C. lower than the "first-hit" value. When the switch is then rezeroed (returned to zero differential pressure) and put on the static variator, the first reading is offset high by approximately 1" W.C. due to this effect.

The remaining 0.5 to 1" W.C. shift has not yet been accounted for. It is believed that this shift is due to the dynamics of the static variator at atmospheric pressure. When starting the test at atmospheric pressure, both high and low sides of the test device are isolated. When the variator is moved to generate a Dp signal, the low side is actually reduced to a slight negative pressure. This has the potential to draw gases out of solution in the test tubing or switch chamber or otherwise create voids in the system.

J

') An attempt was made to duplicate and quantify this effect in a

./ bench test by approximating field piping conditions and substituting a second Rosemount transmitter for the SOR device.

The test results did not duplicate the effect.

Subsequent discussions with SOR, Inc. revealed that they had noticed erratic results in the past while using the variator at atmospheric pressure. They were not sure of the cause of this effect, but surmised it may be related to negative pressure effects on a device requiring some displacement (the SOR switch) l versus a device with little or no displacement (a Rosemount transmitter). Their solution was to per form all "atmospher ic"

testing at a static pressure of 10 psig. To determine whether a negative pressure generated by the variator causes any errors, a follow-on test at 10 psig was performed following a standard static test on a sample of switches.

Additional testing to duplicate or quantify this shift will be to vary the pressure on both sides of the SOR switch and the Rosemount transmitter simultaneously with calibrated pressure devices. This will be done to simulate the simultaneous action of the variator.

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V-35 J

DOCUMENT ID 3~125i

These investigations are purely for the sake of completeness in quantifying all the data. The unexplained portion of the shift O' will not affect the results or conclusions from the testing, since the zero pressure static test setpoint data are not used in the determination of new setpoints or acceptable switch static shift ranges.

2. Accuracy of the Test Measurement i The static variator testing measurement devices consist of a i Rosemount Model 1151 DP transmitter, powered by a 30-VdC power supply with a precision 1-ohm resistor in the transmitter output loop. The Rosemount generates a 4 to 20 mA signal that is read as a voltage drop across the resistor using a Fluke 8060A digital voltmeter (DVM).

Based on the Rosemount manual, the acceptable load range for the transmitter output at 30 Vdc is 0 to approximately 600 ohms.

The output is very insensitive to power supply fluctuations, changing less than 0.005% of output span per volt of power supply voltage change. Variations in power supply voltage are also accounted for by performing before and after test calibrations. The accuracy of the transmitter is 1 0.25% of calibrated span. Rosemount 1152's or 1153's would exhibit similar characteristics.

The precision 1-ohm resistor is accurate to 1 0.00001 ohm (0.001%). Any error attributable to the resistor is

' ( .) insignificant when compared to the accuracy of the Rosemount transmitter.

The DVM has an accuracy of 1 0.04% of input voltage plus 1 0.01%

of range. Its accuracy is also much greater than the Rosemount, and since the accuracy is relative to the range and input voltage, a change in the size of the resistor would not effect the accuracy of the measurement.

Based upon the above accuracies, the test measurement apparatus is considered to be adequate to determine the functional characteristics of the SOR Dp switches. The limits of error in measurement (2a) for the instrument loop used in the test are 1 0.699" W.C., which corresponds to 0.99" RWL when converting

! the readings to vessel level indications.

l l

V-36 DOCUMENT ID 37251

3. Rosemount Static Pressure Zero and Span Correction Factors In the setpoint characterization tests performed with Rosemount b,O differential pressure (DP) transmitters, the elevated pressure data were corrected to compensate for the effects of static pressure on the transmitters in accordance with their l instruction manual. For the transmitters installed on the static pressure test machines, the output span of the instrument l will decrease by 0.5 to 1.0% per 1000 psi static pressure for the same input range depending on the model number. That is, if i the differential pressure remains constant across the transmitter, its output will slightly decrease as the static pressure increases. For example, the span of'a Rosemount model 1153 DP transmitter with a range code of "4" will decrease by

! 0.75% at 1000 psig. If it is calibrated with the low side at atmospheric pressure to provide an output of 4 mA at 0" W.C. and 20 mA at 125" W.C., its output at 125" W.C. with the low side at 1000 psig will be 19.88 mA (20 - 0.0075 X 16). The correlation between the unit's output and the differential pressure across it is given by the following formulas:

At C psig: DP = (I-4)/(16/125)

= (I-4)/0.128 At 1000 psig: Dp = (I-4)/(15.88/125)

= (I-4)/0.127

' Where:

DP = differential pressure in inches W.C.

I = current output of unit in mA.

This method is used to correct all of the elevated static pressure data measured by Rosemount transmitters in the tests.

The static pressure shifts in the span of each Rosemount transmitter used in the tests were measured at static pressures up to 1000 psig in accordance with LaSalle test procedure LST 86-11,4 and found to meet Rosemount's specifications. A table showing how each Rosemount transmitter reading for the LaSalle testing program was corrected when converting the DVM readings to inches of water column at the switch is shown in Table V.3.

The ouput of the transmitters do not need to be corrected for any zero shift due to static pressure because its effects were eliminated by using the zero adjustment. Also, the elevated pressure tests performed on the transmitters demonstrated that the zero shift was negligible and that with the proper adjustment, no zero shift will occur between 0 and 1000 psig.

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V-37 J

j DOCUMENT ID 37251

TABLE V-3 ROSEMOUNT CONVERSION FACTORS FOR SPAN CORRECTIONS Procedure No. DP Test Transmitter Calibrated Correction Factor **

Span 0 psi High Pressure ILST-86-) Swltch No. Date Serial No.

(

99 2B21-N024A 6-11 408413(R4) 0-125 0.128 0.127 2B21-N024B 6-12 408413 0-125 0.128 0.127 2B21-N024A/24B 6-19 29332(R4) 0-125 0.128 0.127 2B21-N024B 6-21 29332(R4) 0-125 0.128 0.127 2B21-N024B 6-23 29332(R4) 0-125 0.128 0.127 101 2B21-NO31A 6-13 (R5) 0-200 0.080 0.0794 2B21-NO31C 6-13 (R5) 0-200 0.080 0.0794 2B21-NO31D 6-14 (R5) 0-200 0.080 0.0794 2B21-NO31B 6-16 414598(RS) 0-200 0.080 0.0794 103 2B21-N037AA 6-14 414598(R5) 0-300 0.0533 0.0529 2B21-NO37CA 6-15 0.0533 0.0529 2B21-NO37AB 6-15 0.0533 0.0529 2B21-NO37CB 6-15 0.0533 0.0529 2B21-NO37BA 6-16 0.0533 0.0529 2B21-NO37BB 6-16 0.0533 0.0529 104 2E22-N006 6-16 408546(R4) 0-36 0.4444 0.4380 105 2E21-N004 6-17 408546(R4) 0-36 0.4444 0.4428 106 2E12-N010BB 6-19 408546(R4) 0-36 0.444 0.4430

-- 2E12-N010CB 6-20 408546(R4) 0-36 0.444 0.4430 s 2B21-NO37DB 7-1 414598(RS) 0-300 0.0533 0.0529 2B21-NO37BB 7-1 0-300 0.0533 0.0529 2B21-NO37BA 7-2 0-300 0.0533 0.0529 107 2B21-N038A 6-17 414598(RS) 0-100 0.160 0.1588 2B21-NO38B 6-17 414598(RS) 0-100 0.160 0.1588 108 2B21-N026AB 6-18 414598(RS) 0-200 0.080 0.0794 2B21-N026BB 6-18 2B21-N026CB 113 2B21-N024B 6-2129332 (R4) 0-125 0.128 0.127 1

l 119 2B21-N024A 6-28 29332(R4) 0-100 0.160 0.1588 2B21-N024D 6-29 29332(R4) 0-100 0.160 0.1588 120 2B21-N024A 6-26 29332(R4) 0-100 0.160 0.1588 2B21-N024B 6-28 29332(R4) 0-125 0.128 0.127 2B21-N024D 6-30 29332(R4) 0-100 0.160 0.1588 124 2B21-N026CB 6-29 29732 0-200 0.080 0.0794

Rosemount range codes.

*DP ("W.C. ) = [(DVM r eading mV)- 4]/ Corr ection Factor V-38 DOCUMENT ID 37251

DRAf1COM VI. CORRELATION OF LEVEL DROP PERFORMANCE VERSUS OPERATIONAL / TIME TEST DATA A. MAGNITUDE OF SETpOINT SHIFT l

During the initial testing of five model B212 switches (2B21-N024A, B, D, and 2B21-NO38A and B), the magnitude of the setpoint shift due to static pressure alone was not sufficient to duplicate the amount of shift noted in the level drop tests described in Section IV.

Although most of the five instruments exhibited some setpoint shift in the nonconservative direction (with the exception of switch 2B21-N024A, which when subjected to elevated static pressure alone was able to exhibit a static shift in both the conservative and nonconservative direction), the amount of the shift was approximately 60 to 70% of the shift noted in the level drop tests.

Not until elevated static pressure was applied to the switch over a period of several hours and the switch was cycled with differential pressure (simulating actual process conditions) did the magnitude of the setpoint shift approach the amount of setpoint shift noted in the level drop tests. For example, the level drop test data for the 950 psig tests resulted in actuation of the switches at the following levels:

Level Drop Test Summary (950 psig)

Test Trip Setpoint (" W.C. at switch /" reactor vessel level)

Number 2B21-N024A 2B21-N024B 2B21-N024C 2B21-N024D 1 66.1/9.0 69.7/3.9 67.6/6,9 65.3/10.2 2 64.9/10.8 68.9/5.1 66.2/8.9 66.6/8.4 The elevated static pressure (over a 24-hour period) time test yielded the following:

24 Hour Time Test (1000 psig) 2B21-N024A 2B21-N024B 2B21-N024C 2B21-N024D 65.97/9.4 69.21/4.8 68.3/6.1 65.6/9.8 The mechanism for setpoint shift appears to be partially dependent on the amount of time the device is subject to the elevated static pressure. Testing several switches over varying amounts of time has shown that the amount of time required to reach full saturation of the static pressure phenomenon is between 12 and 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months . That is, testing has shown that when the switch has been subjected to elevated static pressures for more than 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , there is no further shift in

,setpoint.

O VI-l DOCUM$NT ID 40051/

B. LEVEL DROP TEST 3 VERSUS TEST 4 BEHAVIOR OF SWITCHES Section IV of this report presents a summary of the level drop testing performed on June 2 and June 3. Many questions were' raised

(__

with regard to the interpretation of results of this testing. In . '

general, it can be concluded that the setpoints of all switches were found to be in greater error at higher reactor pressures than at lower pressures. As the reactor vessel pressure was lowered to O N psig, all switch setpoints more closely approached the setpoint at .'

which they were last calibrated. This is a strong indication that the greater the elevated static pressure seen by the switch, the more it will deviate from the setpoint.

In Section VI.A, it was demonstrated that the amount of error is also related to the length of time that the switch was subjected to the elevated pressure, up to a period of approximately 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months , after which there is no additional significant static pressure shift.

However, this still does not explain the behavior of the switches noted on level drop tests 3 and 4, which were both conducted at a reactor pressure of about 500 psig.

The switch behavior in level drop tests 3 and 4 is actually due to a different phenomenon--the cycling phenomenon (see Section V.A). From previous calibration observations, it was noted that when the SOR switch is exercised starting from zero differential pressure to its desired setpoint, and then cycled several times just to its trip and reset point (without reducing the differential pressure to zero in between cycles;, the "first actuation" is always greater than successive actions. The second actuation can be as much as 1" to 2" O- W.C. less than the first actuation. However, if the switch ,

differential pressure is brought down through zero, and back to.the' vicinity of the original setpoint, it is found to trip again atr'or very close to, the "first actuation" on the prior cycle (see Figure III-1).

Just before level drop test 1 and just before level drop test 2, the switches had been calibration-checked and found to be within their instrument-allowable tolerance bands. The procedure of placing the switch back into service requires the instrument technician to equalize the pressure on both sides of the switch (effectively,.

placing zero differential pressure across the switch) before applying the service (normal operating) pressure on the switch. Between level drop tests 2 and 3, the switches were not calibration-checked, however, the reactor water level was brought back up to +55 inches of reactor water level (placing approximately 37 to 38" W.C. across the switch). This differential pressure is low enough to allow the range spring of the switch to complete the travel to its " rest" position.

A lower differential pressure (below the mid-30" W.C. range) does not cause the spring to travel any further.

. i

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O VI-2 DOCUMENT ID 40051/

Between level drop tests 3 and 4, however, the reactor water level never reached the high point it had reached before level drop tests O 1, 2, 3, 5, and 6. The maximum level attained in the vessel between level drop tests 3 and 4 was 36 inches reactor water level (corresponding to 47" W.C. at the switches). The 47" W.C. applied to l the switches is just below the switch reset points, and not enough to j allow the range spring to travel to its complete rest position.

The level drop test 4 shows that each of the switches exhibited first-to-second cycle shift only, whereas in each of the other tests, the level reached in the vessel (or the equalization pressure applied to the switch Just prior to placing them back in service following calibration checks) was enough to allow the switch to perform as it does when the differential pressure had just previously been reduced to zero. The first-to-second cycle shift accounts for apptcximately 2 inches (water column at the switch, corresponding to 2.8 inches of water in the vessel) of the difference in the two 500 psig readings of the level drop tests 3 and 4.

, O 4

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l VI-3 DOCUMENT ID 40051/

1

VII. EVALUATION OF 2B21-NO38B(ADS) FAILURE O A. CALIBRATION HISTORY OF 2B21-NO38B This low level switch was initially calibrated on April 18, 1985, and left with setpoint/ reset values of 63.4/57.4" W.C.

On June 16, 1986, the switch was recalibrated and found to have set / reset values of 81.8/63.1" W.C. This is 11 inches beyond the limiting condition of operation (LCO) of 64.84" W.C. The switch was left at 63.1/56.7" W.C.

Later on June 16, 1986, the calibration was rechecked and found to be 65.0/58.6" W.C., again beyond the LCO, which is the Technical Specification allowable value.

O O

VII-l DOCUMENT ID 39951

B. SWITCH DISASSEMBLY AND INSPECTION s_ / The disassembly of this differential pressure (DP) switch showed normal findings with'the following exceptions, which were investigated further at SOR's factory and are discussed in Section VII.C. (The assembly of the SOR, Inc. switch is shown in Figure VII-1).

4

1. Severe corrosion on spring-end bearing (water was in the bearing at time of disassembly) (see Figure VII-2).

2. Deposits (copper-tone color) and scratches on cross shaft (Item 23)

(see Figure VII-3).

3. Minor wear marks on lower spring seat (Item 28).

4. Unknown deposits in the adjustment cap (Item 36), spring retainer (Item 34), and adjustment screw (Item 32).

5. Adjustment screw (Item 32) had a machining burr on the spring end i (see Figure VII-2).

i SOR Dp switch 2B21-NO38B was disassembled in a controlled manner to l

determine the cause of the discrepant performance of this instrument.

Prior to disassembly, the DP switch was cycled from zero through its trip point and back through the reset point using air pressure. This process ;

was performed with the switch oriented with the mounting bracket on the O bench and rotated 90' to the normal mounting position. This was done to show the insensitivity of the switch to orientation while using air for tripping the switch. This allowed the first orientation to be used during the travel check to be performed next without affecting the measurement results.

The DP switch was positioned with the electrical box facing up for measurement of the switch side lever travel. The microswitch lever total travel, travel from zero to on, and travel from off to zero were measured.

The spring assembly and housing were then disassembled and inspected. The spring assembly looked normal with the exception of deposits found in the adjustment cap spring retainer and adjustment screw and a burr found on the adjustment screw. These deposits made the adjustment screw turn roughly, making fine adjustments difficult. The burt on the adjustment screw caused the spring seat to wobble as the adjustment screw was turned, again adding to the difficulty of adjustment. The adjustment screw was found to have a very loose fit in the spring retainer. The spring seats are not sized to firmly engage the spring to prevent slippage and l nonuniform torque transmission by the cross shaft. The spring lever was determined to be tight prior to removal.

O ,I VII-2 "

l DOCUMENT ID 39951

The high-pressure side of the DP body was opened for examination of the internal parts. All bolts were securely tight when removed. The high-pressure body half was removed using alignment pins so as not to v disturb the position of the diaphragm. The diaphragm was centered and in good condition. Close inspection of the diaphragm halves and polyamide diaphragm showed them to be assembled properly and in good condition. The piston lever set screw was checked and found to be tight prior to its removal.

The cross shaft was removed from the switch end by slowly withdrawing it without rotation to prevent damaging the "O" rings. The cross shaft was visually examined and found to have circumferential scratches and foreign deposits in the area of the dynamic "O" rings / outer sleeve.

The internal spring-side bearing / spacers /"O" rings were withdrawn with a bearing puller. These parts were visually inspected. The spring-side bearing was severely corroded, both internally and on the interior face.of the bearing housing. The bearing contained a drop or two of water when removed from the DP body. The cross body spacers and "O" rings were then removed from the spring side. The switch-side bearing was left in place because it is trapped by the switch housing. The bearing was examined by viewing it from the switch end of the DP body. No corrosion was noted on this bearing. A close examination of the dynamic "O" rings showed a

" copper-tone" foreign material deposited on them. No other abnormal indications were noted on the bearing / spacers /"O" ring assemblies. These items were sent to SOR's facilities for further examination.

O O I VII-3 DOCUMENT ID 39951 1

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Diffsrsnti;l Pr:ssura Switch Int:rnal Parts Figura Vil-2 O

Spring retaining o(

shoulder I

!"N I Spring Seat (Antifriction)

Corrosion products

\\ \\\\ .-

1 O gy Adjustment Screw E xterior surf ace (slight corrosion)

~~~

7 ' Interior surf ace (severe corrosion) 2 Rollers (severe a corrosion troten)

O e ,i e- e ,i .

=_

DOCUMENT ID 39951

l Figura Vll-3 Cross Shaft

+

A"

Copper-tone matenal g3-M W w

0.942' r e---- 1.126" W t

[_

I SP""9 end Switch 9 4 1.228" end

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l (969-f j C?-86-395

\

VII-7 DOCUMENT ID 39951 l

C. SWITCH INSPECTION AT SOR'S FACILITf

[N Af ter 2B21-N038B was disassembled and inspected at LaSalle, it was packed

(,,) in two shrink-wrap packages and transported by SOR, Inc. to their facility in Olathe, Kansas. The switch parts remained sealed until their inspection in the presence of Mr. E. Spitzner of Commonwealth Edison Company - Corporate Maintenance.

The critical shaft components and seals were examined under a 20X microscope for signs of possible damage. They were also examined for compliance with their design tolerances. A report, SOR 8601-018, provided as Appendix H, was prepared by SnR, Inc. detailing the examination and the findings. The folicwing is a summary of the findings.

1. Spring-End Bearing The spring-end bearing (see Figure VII-2) that was found to be corroded during examination at LaSalle was further examined with the use of a 20X microscope and a hook tool. The bearing was determined to be corroded to the degree that the rollers were frozen in place.

A closer examination of the cross shaft in the area of contact with the spring-end bearing showed circumferential scratching caused by bearing contact with the moving shaft.

2. Switch-End Bearing Due to the spring-end bearing problem and the inability to closely examine the switch-end bearing at LaSalle, SOR pulled this bearing for closer examination. This bearing showed no signs of corrosion.

I)

\~- The rollers were coated with lubricant and were all free to turn.

3. Cross Shaft i

The " copper-tone" foreign material found on the cross shaft (see Figure VII-3) was determined to be in the vicinity of the dynamic "O" rings. Deposits of this material was found on both the dynamic and static "O" rings. A small sample of this substance (102 mg) was scraped from the croca shaft using an "O" ring extraction tool and sent to General Testing for quantitative and qualitative analysis.

The foreign material was found to be 100 mg ferric oxide (red rust) and 2 mg nickel.

The scratches on the shaft were both approximately 0.1 inch outboard of the dynamic "O" rings. This is in the vicinity of the dynamic "O" ring / outer sleeve interface although this has not been determined to have caused the scratching.

O 1

l VII-8 l DOCUMENT ID 39951

t

4. "O" Rings The two dynamic and two static "O" rings were examined for the p;esence of foreign material, damage, internal and minor diameter

]O tolerances, flash, and offset. Foreign material was found on all four "O" rings, although the dynamic "O" rings were more heavily coated than the static "O" rings. The "O" rings were found to be within their tolerance or slightly off in a direction that could have I been caused by their use. No abnormalities were determined.

4 5. Lower Spring Seat

- The wear mark noted on the lower spring seat (see Figure VII-2) at j the LaSalle inspection was examined closely by SOR at their facility. There was no evidence of any abnormal wear or gouging.

The lower spring seat exhibited a loose fit (approximately 3/32 inch free motion) with the spring.

1 6. Spring Retainer and Adiusting Cap 1

SOR had a qualitative and quantative analysis performed on the foreign material found in the spring retainer and adjusting cap. The i results of this analysis showed iron oxide with trace metals.

4

7. Adiusteent Screw

! The adjustment screw (see Figure VII-2) did not require further investigation at SOR's facility. The discrepancy noted in the l (\)/

interface with the upper antifriction washer affects the ease of DP adjustment, but not the after-adjustment performance. The thread pitch and fit are per SOR's design specifications.

8. Low Pressure Body Bore I

J The bore of the low pressure (LP) body was examined with an 8X I borescope to determine whether any scratches were present that could i cause leakage past the spring-side static "O" ring to the bearing. .

}

The examination showed no evidence of any scratches capable of

causing leakage. Only minor honing marks and minor casting cracks 1 were noted.

The switch was reassembled both without and with Parker Super-O-Lube and subjected to a helium leak test. It was tested with the shaft in

both static and dynamic conditions. No seal leakage was detected.

! 9. Spring i

[ The spring was examined at SOR for conformance to its design l specification and for signs of abnormal wear. No abnormalities were noted.

lI i

lO i

Vit-9

{

DOCUMENT ID 39951 l

D.

SUMMARY

OF CONCLUSIONS es The inspection of SOR switch 2B21-N038B showed significant corrosion on

( ,) the spring-side needle bearing. The corrosion was sufficient to impede proper performance of the differential switch. This would cause drift in setpoints compounded by erratic behavior as the corrosion was displaced.

In short period cycling, the setpoint could appear stable. As the time period increased between cycling, the setpoint would begin to drift, generally toward increasing differential pressure.

Tine source of the water that caused the bearing to corrode is indeterminate. The distribution of rust on the bearing sleeve and the lack of water in the spring housing point toward an internal source of leakage. However, SOR found no damage to the shaft, low-pressure bore, or "O" rings that would support this theory. Furthermore, a helium leak test of the reassembled switch showed no signs of leakage. It is quite possible that any foreign material that might have caused this very minor leakage was disturbed by the disassembly. The "O" rings were wiped along i

the cross shaft and LP bore during removal of interior parts.

The foreign material in the adjustment screw and the burr on the adjustment screw were felt to create an adjustment difficulty but not to affect switch operability.

The coarse thread (18 threads /in) and the loose fit (class 3) of the ddjustment screw and spring retainer have been seen to cause adjustment screw rotation particularly when the switch is mounted with the adjustment screw down and subjected to vibration. Adjustment screw rotation can affect the switch setpoint.

(}

The loose mating of the spring with the lower antifriction washer permits the spring to move on the antifriction washer in a manner that can changa the torque on the spring lever and, therefore, the setpoint. The antifriction washer should be mated to the size of spring used (each range would have a specific antifriction washer to match the spring's internal diameter).

The adjustment screw fit and antifriction washer / spring fit would be affected by induced vibration in the switch transmitted to the switch by the instrument lines or mounting rack. SOR Dp switches that show larger drif t should be monitored more closely to determine whether these effects are excessive.

2 O

1 VII-10 DOCUMENT ID 39951

VIII. RECOMMENDED TESTI RAH CM DPROGRAMPRIORTOOPER v As described in other sections of this report, an extensive, detailed testing program was formulated and executed to identify the causes of the failures to trip at the specified reactor water level and to accurately characterize switch operation. Based on an evaluation of the data generated by this test program, the switch operation with respect to s atic pressure shift, hysteresis, and repeatability was characterized for each switch type and switch function. The evaluation will also develop acceptance criteria to aid in the procurement of new switches and the calibration and acceptance testing of existing switches. Existing switches will be tested to verify that they meet the criteria for continued use, and new switches will be required to be tested by the manufacturer and certified to meet the same criteria. The setpoint characterization tests are discussed in Section V.D of this report, and test (s) to be performed on each switch are specified in Table VIII-1. In order to confirm the test data evaluation and conclusions, system operational tests will also be performed to verify satisfactory switch operation. The following is the proposed total test program to characterize switch operation and verify function via operational tests.

I. Prior to Startup A. ECCS Minimum Flow Valve Switches

1. Setpoint characterization (see Table VIII-1)

2. Time-related static shift measurement on two switches.(see Table VIII-1)

3. Verify switch function (valve closure) during pump 3 operation while increasing to full flow (see Section V.E.6 for results)

4. Verify switch function (valve opening) during pump operation while decreasing flow to minimum (see Section V.E.6 for results)

B. Reactor Water Level Switches

1. Setpoint characterization (see Table VIII-1)

2. Time-related static pressure shift tests on a sample (see Table VIII-1) j

3. Level Drop Tests I

a. Level 3 switches only (scram, ADS permissive)

b. Two separate tests, one hour apart i

O DOCUMENT ID 39861/00031 VIII-l

C. Break Detection (Flow) Switches

1. Setpoint characterization test (see Table VIII-1)

[V'T

2. Time-related static pressure shift tests on a sample (see Table VIII-1)

II. During Startup j

A. ECCS Minimum Flow Valve Switches

1. Before pulling control rods, repeat tests in I.A.3 and 4 above

]'

B. Reactor Water Level Switches

1. At 1000 psig, after a 24-hour soak, repeat tests in I.B.3 above

2. At 500 psig, after depressurization from 1000 psig testing, repeat tests in I.B.3 above

)

i III. During Shutdown for First Refueling Outage (for reactor water level 3 switches):

A. At 1000 psig, repeat tests in I.B.3 above.

B. At 500 psig, after depressurization from 1000 psig testing, O repeat tests in I.B.3 above.

At 0 psig, after depressurization from 500 psig testing, repeat C.

l tests in I.B.3 above.

l The data from testing in I. and II. will be evaluated for acceptable j

switch operation. When switch operation is acceptable, the SOR DP switches will have demonstrated the ability to perform reliably to suppott safe operation of the unit. Additional requirements for switch

surveillance and calibration are specified in section X of this report.

a l

i O

DOCUMENT ID 39861/00031 VIII-2 I

TABLE VIII-l l

SOR DIFFERENTIAL PRESSURE SWITCH TEST PROGRAM MODEL l SWITCH l l l TEARDOWN & l l INCREMENTAL NUMBER l TAG l MINI OP l FULL OP l INSPECTION l TIME l CALIBRATION

_ l NUMBER l (1) l (1) l l (2) l ,

l

, l l l l l l X X l X l B212 l 2B21-N024A l l l l l l l2B21-N024A l l LEVEL 3 l(New setpoint) l X l l [ X l l2B21-N024B l l l l l X

l (Existina) l l X l l l l l l l l2B21-N024B l l(Replacement) X l l l X l l

l 2B21-N024C l l l l l (Existing) l X l l X l l l l 2B21-N024C l l l l l l (Replacement) l X l l l X l l l l l l l X l X l l 2B21-N024D l l l l l l l l l X l X l l 2B21-NO38A l l l l 2B21-NO38B l l l l l l (Existing) l l X l X l l l 2B21-NO38B l l l l l

'Os l l

(New) l 1

X l l

l l

X l l

X l l l X l l_2B21-N101B l l 86-1-3269 l l l l l l l X l l SPARE l l

! l 86-1-3270 l l l l l l SPARE l l X l l l _

l l l l l l

. B203 l 2B21-NO31A l l X l l l l l l l l l X l X l LEVEL 2 l 2B21-NO31B l l l ._,

l l l l l l X l X l l 2B21-NO31C l l l ____,,

l l l l l l l 2B21-NO31D l l X l l l . _ _ _

l l l l l l X l l X l ___ _

l 2B21-NO37AB l l l l l l l l l 2B21-NO37BB l X l X l l l X_._

l l l l l .I l 2B21-NO37CB l l X l l X l___ _

l l l l l l l 2B21-NO370B l X l l l l _. . . _

O DOCUMENT ID 39861/00031 VIII-3

TABLE VIII-l SOR DIFFERENTIAL PRESSURE SWITCH TEST PROGRAM (Cont.)

SWITCH I l l TEARDOWN & l l INCREMENTAL MODEL l NUMBER I TAG l MINI OP l FULL OP l INSPECTION I TIME l CALIBRATION I (1) I (1) l ._ l (2) l l NUMBER l l l 1 i l

x l l l l B203 1 2E31-N012AA I l l l l RH I l X l l l l HI FLOW l 2E31-N012BA I l 1 I I l l X l l l l l 2E31-N012AB l l 1 I l l l X l l l l l 2E31-N012BB l l l l l l l

X l l l l RH HI STMl 2E31-N007AA l l l l l l l

X l l l ,

l 2E31-N007AB l l l l l l l i l X l l X l I l 2E31-N007BA l l l l l l 1 1

X l l l l l 2E31-N007BB l 1 I I I l 1

X l l RCIC HI I 2E31-N013AA l l l l l l l l

! STM FLOW l X l l l ISOL l 2E31-N013BA I l l l l l l l

X l l l

l 2E31-N013AB l l l l 1 I I I l

X l l l l 2E31-N013BB l l l l l l l l

BB203 l 2B21-N026AB l l X l l l_

l l l l l l

LEVEL 2 l 2B21-N026BB l l X l l l_ ,

I I I I l l X X l X l_ X l 2B21-N026CB l l l l l l l l l l 2B21-N026DB l X l l l l, ._

l DOCUMENT ID 39861/00031 VIII-4

TABLE VIII-1 SOR DIFFERENTIAL PRESSURE SWITCH TEST PROGRAM (Cont.1 MODEL l SWITCH l l l TEARDOWN & l l INCREMENTAL NUMBER l TAG l MINI OP l FULL OP l INSPECTION l TIME l CALIBRATION l NUMBER l (1) l (1) l l (2) l l l l l l l

X l l X l BB205 l 2B21-NO37AA l l l l l l 1 l

X X l l X l LEVEL 1 l 2B21-NO37BA l l l l l 1 ! l l 2B21-NO37CA l l x l l l l l l l 1 l X l l l l 2821-NO37DA l l l l l l l l

l X l B202 l 2E12-N010AA l l l l l RH MIN l l l l FLOW l 2E12-N010BA l l X l l l l l l I I l

l 2E12-N010AB l l l l l l l l l l l l 2E12-N010BB l l X l l l l l l l l 1 2E12-N010CA l l

, l 2E12-N010CB l l l l l LP MIN l l l l l l FLOW l 2E21-N004 l l X l l l HP MIN l l l l l l X l X l FLOW l 2E22-N006 l l l

, (BB202) l l l l l l l l l l l 1 l

l l l l l l l l l l l I B305 l 2E31-N008A l l X l l l l l l l l l MS HI X l X l l 2E31-N008B l l l FLOW l l l l l l l 2E31-N008C l l X l l X l_

l l l l l l X l X l_

l 2E31-N008D l l l ______

O DOCUMENT ID 39861/00031 VIII-5 1

1 i

TABLE VIII-1 SOR DIFFERENTIAL PRESSURE SWITCH TEST PROGRAM (Cont.)

v 1

MODEL SWITCH I I l TEARDOWN & l l INCREMENTAL i

hUMBER l TAG l MINI OP FULL OP l INSPECTION l TIME l CALIBRATION I NUMBER I (1) (1) l l (2) l l l MS HI I l l l X l l X l FLOW l 2E31-N009A l l I I I I l 1 X #l l X l I 2E31-WOO 9B l l 1 1 I I l l X l l l l 2E31-N009C l l l l 1 I 1 l X l l l l 2E31-N009D I l l l l 1 l l

X l l l 2E31-N010A l l l l l l I I l

X l 1 l l 2E31-N010B l l l l l l l l

1 2c31-N010C I l x l l l 1 I I l I i X l l l l 2E31-N010D l l l l l l l

, I X l X l l 2E31-N011A I l l lO i 2E31-No11e l

i l

x X

i l

i i

I l X l

l l

l 2E31-N011C l l l l l l l I l

X l X l l 2E31-N011D l l l X - REQUIRED TEST i NOTE #1 - Described in Section V.D.2.

NOTE #2 - Described in Section V.E.

DOCUMENT ID 39861/00031 VIII-6 l

IX. AMBIEPIT TEMPERATURE EFFECTS Commonwealth Edison has contacted both Oyster Creek and Duke Power relative to the effect of ambient temperature on SOR, Inc. differential pressure switches as suggested by Mr J. T. Beard (NRC). No evidence of an ambient temperature effect has as yet been identified.

These switches are located in the reactor building, which has both heating and cooling systems to compensate for variations in ambient temperature.

Although data on reactor building temperatures are not routinely collected, area supply temperatures were monitored throughout the startup test program. These data indicate that only a 20' to 25'F temperature variation is to be oxpected.

After SOR built the switches, they performed a temperature influence test on each switch. In this test SOR recorded the setpoints of the switch at ambient (70* to 80*F), 150*F, and 212*F. These test data show that temperature has only a minor effect on their setpoints. Between ambient and 212*F, the setpoints for most of the switches changed by less than 1%

of full scale. Therefore, the 20' to 25'F temperature variation that they could experience in the reactor building will have a negligible effect on the setpoints of these switches.

DOCUMENT ID 40031/

1 i

X. JUSTIFICATION FOR OPERATION OF LASALLE UNIT 2 O

l A. GENERAL ELECTRIC SAFETY PARAMETER RANGE ANALYSIS l

1. Overview )

An analysis was performed to determine the maximum allowable range for the safety parameters controlled by SOR switches. This analysis indicates that marked broadening of the instrument operating range is possible for all three of the applications that employ this SOR switch. The more safety-conservative operation of these instruments justifies an OPERABILITY classification based upon the current Technical Specifications for LaSalle.

2. Purpose The purpose of this study was to determine the bounding analytical limits and any interrelated safety system constraints pertinent to the BWR-5 reactors as configured and instrumented at LaSalle County Station. The analytical limits are derived from the safety analysis of the plant. Specifica ly, they represent the parametric values of pressure, level, and flow for the bounding design basis accidents (DBA) and limiting transients analyzed in the FSAR. The analytical limits, therefore, represent the envelope containing the reviewed safety considerations for those applications under discussion.

The analytical limit is therefore defined from bounding events for O the plant; it is also used as the reference for the instrument

" limiting safety system settings (LSSS)" for the safety equipment, which assures that operations conform to previously documented safety analyses (FSAR). The analytical limit is not the safety limit of the plant, but it represents a safety-wise conservative value based upon mathematical modeling that represents the plant and the dynamic processes inherent in bounding events for that plant.

o l DOCUMENT ID 39961/00031 X-1

i The safety limit is purposefully separated from this analytical limit by a prudent safety-margin assigned to insulate against unknowns and

/~'% uncertaintles in the model, the dynamic processes, and the

(_,/ mathematics. Note that the type, character, and performance of the Instrumentation and control system does not determine the safety limit nor the analytical limit. The choice of parameters on which to assign effective limits was determined for the reactor and safety equipment by an operations analysis of the NSSS. For LaSalle, this is included in FSAR Appendix D.

3. Scope of Coverage for Analytical Limits The SOR differential pressure switches addressed in this evaluation are identified in Table II-1. The GE appraisal of pertinent BWR-5 analytical limits and their bases was initiated to depict the fundamental safety considerations, the FSAR calculational models and codes, and other safety-related considerations such as the overlap of ECCS initiation from level 3 and level 2 instruments, for example.

d. Analytical Limits for Level The historical ECCS analytical limits derived from the 1979 FSAR safety analyses were reexamined with more recently approved Appendix K (1984) models. This analysis addressed limiting transients and bounding LOCAs (large and small) to validate that the analytical limits were correct. Additionally, both normal process fluctuations and typical operational events were

,s considered in the selection of suggested operational ranges.

( ) LOCA analyses start (time = 0) with water level initially at

'- ' level 3 when the reactor scrams. The lowest vessel elevation at which a LOCA signal could be taken is at the lower tap of the wide-range water-level (sensor) instruments used for level 1.

The highest vessel elevation at which a LOCA signal could be taken is at the high tap of the narrow-range water-level sensor instruments. Of course, the normal operating range also occurs in this dimension. Also, the level 2 initiation of HPCS and RCIC occurs in this dimension. These interrelations are cited merely to indicate that the typical ECCS accident / transient analytical treatment was required in the validation of analytical limits.

The limiting DBA LOCA from the FSAR Chapter 15 was validated against the safety criteria of the peak clad temperature (PCT) limit (2200'F). Results of the GE analysis show that the revised analytical limits (see Table X-1) provide PCTs that are trivially larger than the original FSAR-computed PCTs (see Table X-2, middle row).

A U

DOCUMENT ID 39961/00031 X-2

The small break LOCAs were also reevaluated with the SAFE-CHASTE-REFLOOD codes used in the original FSAR safety

' analysis. For the small break LOCA yielding the highest PCT in

("

the FSAR (0.09 fta break in the recirculation suction line

\

with HPCS failure), a time comparison showed that a lower water level scram (level 3) would cause the level 1 trip to occur earlier (after scram) than the baseline case in the FSAR.

Therefore, ADS occurs sooner and the low-pressure ECCS flow enters the vessel earlier because the ECCS pump flow can enter earlier (when ADS attains the low pressure permissive).

l It is, therefore, concluded that the more liberal water level analytical limits for LOCA at LaSalle have no impact on the LaSalle LOCA conclusions shown in the original FSAR.

! b. Analytical Limits for Minimum Flow To determine the effect on ECCS response of fully open ECCS minimum flow lines, the ECCS flow curves were reduced on HPCS, LpCI, and LPCS by the full capacity of these pump protection lines. Results show very small PCT increases cF 30'F (large LOCA)and60*F(smallLOCA)buttheresultingIflTsremain

' markedly lower than the maximum PCT criteria of 2200*F (see Table X-2, right column).

4. Results of Analvtical Limits Evaluation

a. Level and Minimum Flow Table X-1 indicates that the historical FSAR analytical limits can be extended for levels 3, 2, and I without compromising safety. This LaSalle-specific analysis took the generic ECCS

analysis of the BWR-5 with generically conservative ECCS pump curves to calculate the resulting PCT for comparison with the PCT limit (2200*F) and the FSAR-tabulated PCT of the Appendix K analysis.

Disclosure that the ECCS minimum flow (permissive) has no significant core cooling effect under the latest Appendix K 1

approved model essentially means that the singular function of these minimum flow indicators is to protect the pump at startup until self cooling is adequate. The logic function to close the l

bypass flow valve when sufficient flow is established through the injection line is no longer necessary. Adjustments to MAPLHGR ilmits or MCPR are not necessary.

l 1

DOCUMENT ID 39961/00031 X-3

l

b. High-Energy Line Break Detection Disclosure of the analytical limits for the high-energy break detection shows the initial bases and essentially no topside or maximum flow ILait. This situation represents the rational instrumentation for break detection: essentially a bang-bang detector that operates on the low-volume end of a potentially high-flow region. GE essentially concludes that the instrument span determines the maximum flow indication (practical operational saturation of the flow instrument rather than any Jominant system flow rate as a function of time). This appears to be the prudent way to represent a break detector as a bell ringer indicator that a break has occurred. No safety system l responses are integrated into these break indicator circuits.

! 5. Conclusion l

Considerable liberalization of the analytical limits are indicated in the GE report. These revised analytical limits are included in Table X-3, which lists the enlarged instrument ranges possible with the GE-revised analytical limits.

O i

1 DOCUMENT ID 39961/00031 X-4 ' ,

t t

t l

i l

I i TABLE X-1 4

E l .

ANALYTICAL LIMITS ON LEVEL i

? Level Trip Used in used in Previous Anaivsis This Analysis

) Points I L3 7.5" RWL - 10.5" RWL i

I L2 -70" RWL - 97.9" RWL J

Li -149.5 RWL -161.5 RWL

!t b

f P

A t I

i i

n l

I I

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! DOCUMENT ID 39961/00031 X-5 l

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TABLE X-2 O. PEAK CLAD TEMPERATURES Updated New Level New Level Case FSAR Analytical Limit Analytical Limit j Analyzed Analysis (Current Flow) (Reduced Flow *)

i f No Estimated DBA 2019'F Significant 2050*F

! Change

! Worst No j Small 1736'F Significant 1794*F

! Break Change i

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Reduced ECCS flow means that flow injected into the vessel when the i j minimum-flow bypass lines are fully open; i.e., the rated ECCS pump flow minus

{ the full capacity of the minimum flow line.

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I 1 1 a DOCUMENT ID 39961/00031 X-6 ;

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TABLE X-3

() POTENTIAL RANGES WITH REVISED ANALYTICAL LIMITS Potential Ranges Potential Ranges 4

with Existing with Revised Ana1Ytical Limits Analytical Limits Reactor Level Level 3 7.5" to 29.5" RWL -10.5" to 29.5" RWL l

Level 2 -70.5" to -10.5" RWL -97.9" to -10.5" RWL l

1 Level 1 -149" to -114.7" RWL -161.5" to -111.7" RWL RCIC/RHR Steam Flow Isolation 114" W.C. to 88.1" W.C. 200" W.C.* to 88.1" W.C.

MSL High Flow Isolation 123.5 psid to 99 psid 178 psid to 99 psid RHR Suction High Flow Isolation 121.5" W.C. to 82.6" W.C. 200" W.C.* to 82.6" W.C.

RCIC High Flow Isolation 200" W.C.* to 170.5" W.C. 200" W.C.* to 170.5" W.C.

HPCS/RCIC High Reactor Wates Level 60" to 42.5" RWL 71.5" to 42.5" RWL Min. Flow Valve Operation s RRR Open: < Specified Flow Open: < Specified Flow LPCS HPCS Close: When full flow close: Not Required Injection Req'd J

Upper erid of range limited by instrumerit range 4

O DOCUMENT ID 39961/00031 X-7

B. CALIBRATION PROCEDURE REVISIONS

\ Based on the GE setpoint limit evaluation and the results of testing

[l

\~- performed to date, existing calibration procedures will be revised to ensure that the SOR DP switches continue to perform properly and that degraded or failed switches are detected. The revisions to the procedures will be made based on the following considerations.

1. "First-Hit" ("As-Found") and "As-Left" Requirements Current procedures include recording "as-found" data on switch operation after approximately three switch cycles. Test data indicate that switch cycling can affect the actuation point, usually bringing it closer to a desired value. To eliminate this effect, revisions to the following three main procedure areas will be made,

a. Clarification of the Method Used to obtain the "As-Found" setpoint for the Instrument In order to obtain the true "as-found" setpoint of the process sensing instrument under test, it is imperative that the i

instrument not be cycled prior to obtaining the "as-found" set and reset values. Therefore the instrument's first actuation point when cycling from zero DP (for increasing DP actuation) or from full range DP (for decreasing DP actuation) is to be recorded as "as-found." From our testing program we have

! identified the effects of cycling on the switches and therefore are changing our procedures to obtain the most accurate "as-O found" setpoint for tracking the instrument's first actuation.

Proper setpoint Adiustment Techniques to obtain the Most b.

Accurate "As-Left" Setpoint for the Instrument In order to reestablish switch repeatability after a setpoint adjustement is made on the switch, it is necessary to slowly and carefully apply pressure as required to cycle the instrument from zero DP or full range DP (depending on increasing or decreasing DP actuation) through its setpoint until three repeatable set and reset values are obtained. (The switch

should be slowly and carefully cycled approximately five to six times from zero or full range DP through its setpoint after a range spring adjustment is made.) The third repeatable set / reset shall be recorded as the "as-left" for the instrument.

O i DOCUMENT ID 39961/00031 X-6 i _ _ . _ _ _ _ - - - . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ,. __ -

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' c..' Cautions Against Overrancina/Underranainq the Switches During Calibration Several cautions have been incorporated throughout the calibration procedures that stress slowly and carefully raising

' ,or lowering-the operating parameters of the switch from zero or full range-DP through its setpoint to avoid unnecessary

- overranging or underranging of the instrument. Precautions also l

are necessary for connecting and disconnecting the instrument fromt{etestequipmentusingtheappropriatevalvingsequence.

l In conclusion, with the improved calibration techniques and surveillances for the SOR differential pressure switches, the i performance characteristics of the switches can be selectively 4 controlled to meet the operating Technical Specification parameters.

j 2. Static pressure Offset Evaluation The test data have been evaluated and reduced to provide expected

' operational tolerances.for the SOR DP switch setpoints. The switches have been grouped by model number and function (level, flow, etc.) to provide operating tolerances for each specific plant application.

The static pressure offset is calculated by averaging the deviation

' from the original desired setpoint or "first-hit" actuations for each satisfactorily performing switch operating at the same setpoint and including a 2a deviation from the mean. The a's are sample standard deviations, which provide a more conservative value than the

]

population standard deviation values. The static pressure offset is 4 then determined by the 2a values for the most nonconservative, 4

acceptably performing switch in a group. This statistical bound of

' the offset value was then used to determine appropriate switch setpoints.

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3. Revision of Setpoints The offset values discussed in the preceding subsection have been l used to justify existing setpoints or define new setpoints such that the entire operating tolerance will remain equal to or more conservative than the existing Technical Specification nominal trip j

setpoints. This will give high assurance that the actuation point I will remain conservative relative to the nominal setpoint while retaining the existing allowance for drift between the nomir.a1 setpoint and the Technical Specification allowable value that is the limiting condition for operation (LCO). The criteria used in selecting revised setpoints are illustrated on Figure X-1. Although the GE evaluation discussed in Section X.A identified very large j

differences between the Tech. Spec. LCos and the analytical limit, the currently proposed setpoints will not take advantage of the margin ~available. Instead, the setpoints will be revised in the conservative direction, where necessary, using the GE operational 7

limits and LaSalle Station operating experience as a basis to avoid inadvertant trip actuations. Based on the data available today, revised setpoints are DOCUMENT ID 39961/00031 X-9

expected to be required for the reactor water level switches (levels 1, 2,

/~' 3, and 8), the ECCS pumps' minimum flow valve flow switches (LPCs, HFcs,

( RHR/LPCI), and the main steam line high flow isolation switches. The remaining switches, used for RCIC and RHR high-flow isolation signals, are '

not expected to change at this time.

The following calculation was used to develop _the new level 3 setpoint for __

the reactor low water level (also see Figure X-1 for the criteria ,

definitions). Similar calculations have been performed for all applications requiring a revised setpoint, l

Reference:

"W.C. = 72.59 - ("RWL/60)

42.297 Given: NTSP = 12.5" RWL at the switch "RWL = (72.59 "W.C.) 60/42.297 3o1000 = 1 2% of the instrument '

Adjustable range ***

Adjustable range = 7 - 100" W.C.

(0.02) (93) = 1.86" W.C. A=T + B = 1.05 + 1.86 = 2.91" W.C.

3a1000 = 1.86" W.C.

C = 1.5

3ao = 2.79" W.C.

X = Largest " acceptable" offset = 3.0" W.C. (verified by test data) ,

/ t = 1.05" W.C. (provided for in Tech Specs, 3ao = 3a1000 (by definition for it is the "W.C. equivalent to for reactor water the difference between the level 3 12.5 NTS9 and the 11.0 LCO)

B = 301000 = 1.86" WC (*** temporarily defined at i 2% of instrument adjustment range)

(*** temporarily defined at i 2% of instrument adjustment range) o (See Fiqure X-1 for definitions of A, B, and C)

Perform the following to calculate the new setpoint: . 4

1. Convert the 12.5" RWL to equivalent "W.C.

(72.59 - (12.5/60)

42.297) = 63.78" W.C. .

2. New setpoint = (NTSP - 3a1000 - X) "W.C.

= (63.78 - 1.86 - 3.0) " W.C. = 58.9" W.C.

3. Convert to "RWL = (72.59 - 58.92) 60/42.297 = 19.4" RWL (New Setpoint)

Upper Band (RWL) Lower Band (hWLI Refer to Figure X-1 3a o 57.06" W.C. s22.0 60.78" w.C. 16.8 s

) for band representations C 56.13" W.C. 23.3 61.71" W.C. 15.4 A 56.01" W.C. 23.5 61. 83" 14.C. 15.3 DOCUMENT ID 39961/00031 X-10

() Switches found outside the "C" band will be recalibrated and monitored in the LaSalle trending program for continued evaluation. Switches falling outside the "C" band during two successive surveillances will be considered inoperable and will require replacement and/or disassembly and inspection.

Switches falling outside the "A" band will immediately be considered inoperable. Spare switches will require complete testing to satisfy the same requirements as new switches prior to installation in the plant.

i Note that if a setpoint drifts more than the administrative span "C", the surveillance interval will be reduced to the interval of the last successful surveillance.

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O DOCUMENT ID 39961/00031 X-11 s

Figura X-1 Recommended Criteria for Selection of New Setpoints and for Acceptance / Rejection p Decisions During Surveillances ;

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I (NTSP 3 1000*K'AI J L A

,, -- -- -- (NT SP-3 1000-X-C)

,,-,-,,,,,,,,,-,-,-,-,-,-,-,---,-*-a-,-,, , ~ , - . ,-,-,* (NTSP 3"1000 X 3 ,)

d' C Ir 3a '

instrument setpoint. when cahbrated at 0.0 poig u II (NTSP 3.'1000 X)

' bk AL 3 ', C o

,-,-. ,,- ,- , ,,- ,- ,- ,- ,- , ,,- ,- ,- ,- ,- ,- ,. ,-,-, .,-,-,, (NTSP 3 '1000-X - 3 ,)

Surveillance acceptance critens based on 1.5

3d, T.

z If E

- (NTSP-3 '1000 X A)

- Surve6llance rejectio.i critena

based on finding the switch in error at 0 psig

.5 exceeding the LCO equivalent at 1000 psig W

o h

e o

t

: Largest

acceptable' static pressure offset determined D X from LaSalle (and future SOR) test programs (X)

{E 3

Y.

5 o

E

- ,-,-,-,-,-,-,-,---,-,- ,- ,- ,- , - , - , - - - , - , - , - , . ( N T S P - 6 j og o )

{ -, * , - , - .

8 1f Desired inp point IL ' Deviation of desired setpoint from NTSP (B s

- =*,------*=*NTSP y -, - - - , - - - - - - , - , - - - , - - - - - - - * = , - - - , - * - - -

Allowance for Total error due instrument drift (-) to random actuations at 1000 psig and time dnft phenomena ( A)

IP 1P LCO NOTE: Until these values have been validated by the manuf acturer, the existing suggested values of :2% of adjustable range will be used.

is a number provided by manufacturing to describe as designed repeatability performance of the model when

oghted su to 1000 pelg static pressure.

O ~o,is a number provided by manufacturing to Oescribe as-designed repeatability periormance of the model when

! subjected to 0 pelg static pressure.

I 6959-9 07 EE-395 DOCUMENT ID 39961/00031 X-12 l

C. SURVEILI.ANCE REVISIONS

\r 1. Frequency Required The surveillance interval for the SOR differential pressure switches will begin at 2 weeks for all of the model B212s and representative samples of all other models. This interval will be increased in 1-month increments, which would lead to the following testing schedule after startup: 2 weeks, 4 weeks, 2 months, 4 months, 7 months, and so forth.

New administrative limits and a reject limit have been established for each switch function. These are based on test results and the setpoints.

If a setpoint drifts more than the administrative span, the surveillance interval will be reduced to the interval of the last successful surveillance. The interval will not increase until two successive surveillances have been satisfactory.

Any switch that drifts beyond the reject limit will be replaced.

Also, any switch that drifts beyond the administrative limit in two successive surveillances will be replaced. Replaced switches will be held for inspection by appropriate parties.

In addition, all SOR calibration data will be graphed to identify trends.

2. Acceptance Criteria As discussed in Section X.B.2, a range of acceptable values will be identified for each switch model and function. Suggested values based on existing data are shown in Table X-4. These acceptable values will usually be the same as the 2a offset values. Values will be specified both for 0 psig and for normal operating pressure and will include the acceptable range about the static shift and about the procedural trip setpoint at 0 psig. For applications with very tight bands between the Technical Specification nominal setpoint and the operational limit, these constraints may define the acceptable values instead of the statistical data from existing switches.

a. New Switches New spare or replacement switches will be tested by the manufacturer to demonstrate performance within the specified allowable tolerance values. Switches that operate outside the band defined by the two standard deviation data will be rejected. Consecutive "first hits" at 0 psig will also have to meet repeatability criteria for acceptability.

O DOCUMENT ID 39961/00031 X-13 g

b. Existing Switches During subsequent surveillances, installed switches will be O, checked at 0 psig and verified to be repeatable within the specified band. Switches found outside this band will be recalibrated and monitored in the LaSalle surveillance trending program for continued evaluation. Switches falling outside this i

band during two successive surveillances will be considered

inoperable and will require replacement and/or disassembly and inspection. Switches falling outside the band by greater than a specified value will immediately be considered inoperable.

Existing spare switches will require complete testing to satisfy the same requirements as new switches prior to installation in the plant.

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DOCUMENT ID 39961/00031 X-14

TABLE X-4

\ PRELIMINARY ACCEPTANCE CRI7ERIA Acceptable Maxirman Switch Calibration Calibration Static Tech. Spec. Setpoint Acceptance Reject Pressure Nom. Setpoint Exist./ Revised 8and (" W.C.) Band (" W.C.) Offset Parameter 34.2" W.C./38.7" W.C. $2 2.7" W.C. 21 2.7" W.C. 3.5" W.C.

Rx. Water 1 33.46" W.C.

Level 8 5 55.5" RWL (54.5" RWL /48.0" RWL) 63.1" W.C./58.9" W.C. 5 g 2.7" W.C. t i 2 .9" W.C. 3.0" W.C.

Rx. Water 5 63.78" W.C.

Level 3 (Note 1) 112.5" RWL (13.4" RWL /19.4" RWL) 143.5" W.C./134" W.C. 52 5.4" W.C. tt 8.6" W.C. 8.0" W.C.

Rx. Water 5145.6" W.C.

Level 2 2 -50" RWL (-47" RWL /33.8" RWL)

Rx Water 5 202.17" W.C. 200" W.C. /189" W.C. 51 7.8" W.C. ti 10.2" W.C. 8.0" W.C.

Level 1 1 -129" RWL (126" RWL /-110.6" RWL)

MSL Hi Flow Isolation (Note 2) 5 111 psid 108.5 psid /102.8 psid 53 8.7 psid 33 10.8 psid 5.d psid 117" W.C. /117" W.C. ti 5.4" W.C. 8" W.C.

RHR/RCIC Hi 52 5.4" W.C.

87" W.C. / 87" W.C. 53 5.4" W.C. t3 5.4" W.C. 8" W.C.

m Stm. Flow Isol 5 123" W.C.

}

RHR Hi Suct.

170" W.C. /170" W.C. 52 5.4" W.C. t1 5.4" W.C. 8" W.C.

Flow Isol. 5 180" W.C.

RCIC Hi Stm.

170" W.C. /170" W.C. 52 5.4" W.C. 5.4" W.C. 8" W.C.

Flow 1501. 5178" W.C. t Min. Flow 13.3" W.C. /230" W.C. 52 1.0" W.C. 23 4.0" W.C. NA 1 5.9" W.C.

Valves RHR t 1000 gpm (1500 g;n /1977 gpm) (Note 3) 11.0" W.C. /23.0" W.C. 51 1.0" W.C . 23 4.0" W.C. NA LPCS t 4.38" W.C.

t 750 gpm (1189 gpm /1719 gpm) (Note 3) 18.1" W.C. /23.0" W.C. 5 g 1.0" W.C. 23 4.0" W.C. NA HPCS 2 9.7" W.C.

3 1000 gpm (1367 gpm /1540 gpm) (Note 3)

NOTES:

1. The 3.0" W.C. maxirman acceptable static pressure of fset will require selective sampling of new or replacement switches in the future.

2. The 5.5-psid maxinun acceptable static pressure offset will require selective sampling of new or replacement switches in the future.

3. For the ECCS mininun flow valve control switches, the setpoint was shif ted so much conservatively higher

[.~ than the NTSP that the measured static shif t was not considered to be a factor for acceptance / rejection.

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DOCUMENT 10 3996i/0003i X-15

XI. WHY LASAL AFTC014 pISCURRENTLYUSINGSORSWIT A. HISTORY OF OPTIONS THAT WERE AVIALABLE The historical sequence of events concerning the selection of and experience with the SOR switches is found in Table XI-1. The following is a discussion of some of these events and their interrelations.

The nonacceptability of Barton 288A/289A differential pressure switches for safety-related applications at LaSalle was first declared by the NRC staff during a June 1980 environmental qualification (EQ) audit against NUREG 0588 Category II standards (Reference LaSalle SER No. 2). An NRC audit of GE records and methods at San Jose in August 1980 covering their ,

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"EQ program" confirmed that the Barton 288A/289A switch was not qualified '

for nuclear service per the NUREG 0588 standard.

Under Edison's committment of October 1980, following the second NRC audit for EQ conformance, the Barton devices were designated for upgrade or replacement to qualified devices. This decision was based on the materials analyses of the 288A/289A model, which showed inadequate radiation tolerance, humidity and thermal inadequacies in hypothetical LOCA environments, and an operational history of drift and calibration problems as evidenced by the volume of LERs written by the industry on the Barton devices.

During this time period (1980-1983) of new EQ requirements that were not then formalized into law, there was uncertainty in industry concerning EQ programs. As a result, subvendors/ suppliers were withdrawing from the marketplace because of the Part 21 burden. With the added requirement for L test demonstration of equipment adequacy to seismic and environmental standards, the subvendors only selectively accepted orders. In fact, the specification of requirements to subvendors was still a problem at NSSS vendor level.

The status of options in 1980-1982 period can be briefly stated as follows:

1. The 1976 design of the Barton devices had evolved into the 288A/289A configuration by the time these devices were delivered to LaSalle for installation during 1980-1982. GE relied upon Barton to fulfill the system specification for reactor water level (RPS) or other applications such as break detection on high energy lines. That initial specification did not discuss EQ matters but referenced the ;

IEEE-323(1971) standard for class lE devices. GE considered upgrading the 288A/289A to a qualified model (which eventually became the Barton 580) but the schedule for qualification could not be predicted until 1983. Another 18 months would pass before completion of the testing. The probability of a successful qualification was l under GE control where a generic objective preceeded the LaSalle I specific qualification objective, hence this option was less than l promising.

O DOCUMENT ID 40061 XI-1 l

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2. The Rosemount 1151-52 instruments were analyzed and did not meet the EQ standards. As a result, they were diverted to uses where harsh

(-m

- environments did not require the high exposure capability demanded of fully qualified equipment. Rosemount 1153 series devices were being tested at Wyle Laboratories under sponsorship of a consortium of utilities. In 1982, difficulties persisted in the testing and in the l

original test specimens. Completion of the Rosemount testing was

! uncertain. Additionally, GE's design of the BWR-5 required the use of mechanical, rather than electronic, level measuring devices for reliability reasons. Edison was advised against the employment of Rosemount differential pressure switches for water level

' measurement. Diversity of equipment was an added reason.

3. Foxboro devices were not qualified at that time. The use of Foxboro equipment, while rather extensive in PWR reactors, is not standard on BWR reactors. The potential use of such devices on the LaSalle reactors was remote.

4. Gould devices fit the general category of possibility ascribed to Foxboro devices, except that the normal power off with power on to function model was being investigated for use in the alternate rod insertion (ARI) scram system. Lead time was adequate for Gould to i

develop and fully qualify any devices needed for that backup scram system only.

5. SOR devices were used in several other applications in the plant s where materials upgrades could result in full qualification for nonharsh environments. This upgrade was planned by Edison. SOR, Inc. had several thousands of pressure switches and differential pressure switches in the petrochemical industry where service requirements exceeded those of the nuclear industry except for radiation. The inherent ruggedness of the SOR devices had been evaluated in Edison's seismic qualification program. In May 1982, following discussions with SOR on their prototype model of a nuclear-grade pressure switch, a decision was made to try to replace Barton devices with upgraded SOR devices that incorporated more radiation and heat resistant materials for'which Edison had EQ data.

The definition of materials and a more rugged bracket for seismic mounting were accepted by SOR. A parallel developmental effort ensued with SOR doing the engineering performance testing to demonstrate repeatability, reliability, stability, etc., and with Edison performing the EQ testing at Wyle Laboratory to qualify the device.

i concurrent testing of the D102/103 prototype began in late 1982 at SOR and at Wyle in early 1983. SOR conducted early testing at Acton Laboratories and at Duke Power. Meanwhile, Edison assisted SOR in establishing a QA program at their new plant in Olathe, Kansas.

During this period Edison finalized the T-3702 specification for EQ qualified devices.

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l j DOCUMENT ID 40061 XI-2 )

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TABLE XI-l DIFFERENTIAL PRESSURE SWITCH MILESTONES December 1976 GE quoted the option for transmitters and trip units for LaSalle as an indacement for their updated control and instrumentation package, which became known as EGCS (Electronic Gener11 Control System). Edison refused and stayed with relay control systems.

November 1979 Draft NUREG 0588 circulated: requires full test basis for Category I equipment acceptability and test data basis for i

l Category II equipment acceptability; cites documentation j

requirements; uses 31 March 1980 as division date (Purchase) between equipment categories I and II.

Up to 1980 Barton switches installed as part of original NSSS contract.

January 1980 IE Bulletin 79-OlB issued to operating plants: allows the use of historical operating data and threshold (text book) data for EQ data base. Known as DOR Guidelines also.

These are lesser EQ requirements than NUREG 0588.

February 29, 1980 NRC Memorandum and Order CLI-80-21 issued to impose DOR guidelines or operating plants and NUREG 0588 on NTOL plants as the EQ requirements. Cited Dec. 1980 compliance objective. (Specific plants received confirming orders A during Aug 80-Oct 80 period. LaSalle requirement to NUREG 0588 confirmed to CECO via staff rejection in Feb 80 of initial DOR-type submittal, which was never reviewed.)

June 1980 NRC-NRR performs first EQ audit of LaSalle EQ documentation against NUEEG 0588 requirements; NSSS equipment fails audit because the vendor had relied on a DOR-type data base that was inadequate.

August 1980 NRC-NRR audits (GE San Jose) for EQ program conformance on LaSalle equipment within NSSS scope; rejects methodology and documentation and cites need for EQ revisions to obtain operating license.

September 1980 CECO issues " Justification for Interim Operation," for LaSalle to support operation through first two fuel cycles with installed NSSS equipment. This was supported by complete operational analysis of plant against all accidents / transients and a thorough analysis of EQ capability under 0588 standards of type-items in LaSalle control and instrumentation applications (approximately 600 safety-related devices).

O DOCUMENT ID 40061/00031 XI-3

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TABLE XI-l (Cont.)

October 1980 NRC-NRR performs second audit of LaSalle EQ program and documentation; accepts CECO commitment: 1) for EQ testing at Wyle Laboratory of equipment whose analysis indicated potential to meet 0588 Category I requirement and 2) for upgrade or replacement of devices whose analysis (or other test data) indicated failure to meet Category II requirements, in which case the upgrade or replacement item must meet full testing requirements of 0588 Category I.

May 1982 S&L/ Ceco /SOR discussed the possibility of replacement of Barksdale and Barton switches with SOR because of EQ concern.

Spring 1982 EQ program documentation for LaSalle project standardized:

Test Plans with backup. materials evaluations for component / parts showing capability. Test procedures and data reports, EQ binders.

i SOR prototype D102/103 built with CECO bill of materials

! for engineering and qualification testing.

August 1982 Issued Specification T-3702 for comments.

Fall 1982 Engineering performance test proceeding at SOR and Acton g Laboratories followed later with tests at Duke Power:

Barton, SOR, and Foxboro devices tested in parallel by SOR.

February 1983 10 CFR 50.49 EQ law became effective; it allows completion of 0588 Category. I testing with a double-hump LOCA requirement added.

June 1983 CECO authorized EQ test for Barton and SOR switches.

EQ testing of D102/103 prototype begins at Wyle Laborotory to modified Category I requirements. Barton and SOH devices tested together on same plan.

i September 1983 Issued Specification T-3702 for bids.

Fall 1983 Engineering performance test at SOR showing SOR device drift to be one-tenth than that of Barton device and equivalent to that of Foxboro device.

December 1983 SOR quotation #021 for pressure switches received.

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DOCUMENT ID 40061 XI-4 s

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TABLE XI-l (Cont.)

o May 1984 EQ test at Wyle turns up temperature-humidity problems with Barton device during LOCA tests at Wyle Laboratory. SOR device still functioning normally. CECO P.O. 287842 for SOR Pressure Switches.

June 1984 Barton device fails on fifth day of LOCA test at Wyle Laboratory; SOR device completes test okay.

July 1984 CECO authorized S&L to install SOR DP switches.

December 1984 SOR quotation #061 for DP switches.

January 1985 Change Order B issued for DP switches.

February 1985 S&L issued ECNs for replacement of Barton DP switches.

In a letter to the NRC, Ceco committed to replace the Barton switches with SOR switches.

April 1985 SOR devices installed as replacement modification for LaSalle Unit 2 level switches, Barton's removed.

Hay 1985 Completed replacement of the Barton switches on Unit 2 with SOR switches; performed first calibration as part of installation testing.

On Second calibration of level 3 switches.

\s / August 1985 November 1985 Committment to complete Unit 2 EQ Modifications.

January 1986 Third calibration of level 3 switches.

March 1986 Fourth calibration of level 3 switches.

June 1986 Feedwater transient event in which only one of four SOR switches tripped at or above the Technical Specification allowable value. Out of specification condition demonstrated by reactor water level drop test on day following the incident. plant shut down to resolve SOR switch problem.

a DOCUMENT ID 40061/00031 XI- 5

B. EO PERFORMANCE TEST RESULTS Records for the environmental qualification of the SOR devices are in Binder EQ-LS075, which is a controlled document. The seismic qualification file is CQD-021103, which is a subordinate record to the EQ binder. These records were reviewed against the NUREG-0588 Category I checklist by Sargent & Lundy, Engineers (S&L) and released under S&L's QA coverage. Edison has reviewed these records and approved their use via a standard project review process. These records indicate full qualification to Category I requirements of NUREG 0588 (IEEE 323-1974 and IEEE 344-1975 as industry standards).

performance records on the prototype D102/103 development testing were retained at SOR; however, an engineering data package for delivered SOR devices accompanied the hardware when delivered to LaSalle. These records indicate the performance characteristics of the particular device. These packages contained certificates of conformance, general instructions, shipping orders, test data sheets, hydro test procedure, dimensional drawings, and test certificates. These records are filed with the purchase specification at the station. Test data sheets indicate pressure integrity, static pressure influence, temperature sensitivity and electric circuit integrity as well as function (switch opening and closing). These packages indicate conformance to purchase orders and QA requirements as well as providing some user's information. They are not the source of design adequacy data equivalent to the SOR file on development testing which is resident at the Olathe plant. The data sheets provide data that are useful for instrument calibration and usage (range limits, overtravel and undertravel, resistances, etc.) Setpoint data are also included for the factory settings.

DOCUMENT ID 40061 XI-6 l

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g C. ORIGINAL DESIGN REOUIREMENTS S&L Specification T-3702 with changes through September 2, 1983, defines the original design requirements. The original purchase order was issued May 16, 1984; it is PO No. 287842 in response to SOR quotation number 021 dated December 22, 1983, as supplemented by a letter of March 19, 1984.

Change orders were added to this purchase order for each incremental ,

l shipment of SOR devices for LaSalle; they cover the period from August 1984 to November 1985. Each order or change order was accompanied by data sheets describing each instrument with respect to service conditions, materials, pressure rating, range of action, type / rating of electrical parts, housing, mounting, EQ and seismic category and requirement, electrical class, and particular SOR catalog number that completes the configuration data. Certificates of conformance from SOR indicate agreement with these specifications under the SOR QA program. The existing numbering codes, coloring codes, CECO standards, S&L drawings, etc. were referenced for SOR use.

The initially specified setpoints for'the SOR differential pressure switches that are used for water level control in the reactor were referenced to vessel level in contrast to instrument range. This resulted in field establishment of the instrument setpoint at a later time. The decreasing water level is indicated by an increasing differential j pressure; the reference leg of the water-level measuring equipment z emains o constant as the high-pressure side while the variable low-pressure side I I

decreases in depth, thus making the differential between the two columns increase. This recalibration was initially accomplished during O calibration in the field.

)

l O

DOCUMENT ID 40061 XI-7

D. EVALUATION OF GENERIC LETTER 84-23

Background

f) v 1.

This generic letter, which was dated October 26, 1984, references S.

Levy Inc. Report SLI-8211, " Review of BWR Reactor Vessel Water Level Measurement Systems." The subject is concern for the following three items:

a. Reduction of* level indication errors caused by high drywell temperatures.

b. potential replacement of mechanical level measurement equipment with analog trip units fed by electronic level transmitters.

c. Elimination of operator action required to mitigate the consequences of a reference leg break plus single failure of a protection system channel on the intact reference leg.

Of the above items, only item b. relates to the SOR switches, and no discussion of items a. and c. will be provided in this report.

2. Short-Term Considerations These concerns for BWR level-indicating systems were addressed for the short term with the following responses in the FSAR: Appendix L.39.1, which cites the GE NEDO-24708A bases document on BWR water

/ level systems; Papendix L.67.1, which identifies the common reference

(- point for water .evel measurements in the vessel; and the response to question 031.287, which describes the reference leg, postaccident level indication of actual water level, and impact of level measurement errors on prior safety analyses as related to trip-point actions beyond those used in the original safety analysis.

3. Long-Term considerations

a. Replacement of Mechanical Level Switches with Analog Trip Units and Level Transmitters The formal response to generic letter 84-23 was transmitted to the NRC by CECO letter of December 4, 1984, from G. Alexander to H. R. Denton (see Appendix G).

At the time LaSalle was licensed, no level switch or differential pressure transmitter was qualified per NUREG 0588, Category I or II; therefore, consideration of a different level measuring device was nil. In fact, Edison had to encourage SOR as a vendor to develop a qualifiable device, which Edison qualified by testing to meet 10 CFR 50.49 requirements. The BWR-5 specification from GE did not allow use of nonmechanical i

DOCUMENT ID 40061/00031 XI-8

devices for level measurement at that time. Only since the

(' ' Rosemount 1153 devices have become qualified has GE revised their BWR specifications to incorporate electronic transmitters

\ and trip units to be utilized in the water level applications.

Edison tested the SOR level devices against the Barton equivalent and concluded that the SOR device was easier to work with. Its characterization by SOR showed less time-dependent drift (as the Technical Specification defines drift).

For the long term, the replacement option for transmitters and trip units remains open. Since the extent of experience with those devices in the reactor water level application is extremely limited, it is considered premature at this time to commit to a replacement, as suggested in the generic letter, with another new device.

b. Closure In response to the CECO letter of December 4, 1984, a letter from A. Schwencer to D. Farrar on March 26, 1985, indicated acceptance of SOR mechanical switches in lieu of analog trip systems (see Appendix G).

O

O DOCUMENT ID 40061/00031 XI-9

i O

O Appendix A LIS-NS-201: Procedure for Low Water Level Scram Switches l

SARGENT S LUNDY O

=_

LIS-NB-201 R3 vision 1 August 2, 1985 1

O UNIT 2 REACTOR VESSEL LOW WATER LEVEL SCRAM AND PRIMARY CONTAINMENT ISOLATION CALIBRATION A. PURPOSE The purpose of this procedure is to outline the method used to perform the Unit 2 Reactor Vessel Low Water Level Scram and Primary Containment Isolation Calibration.

B. REFERENCES

1. S&L P&ID Unit 2: M-139, Sheets 4&5.

2. S&L Schematic Diagrams: 1E-2-4215 AC-AF.

3. S&L Schematic Diagrams: 1E-2-4232 AF and AM.

4. EQ-LS075, " Environmental Qualification Report For Static 0 Ring Differential Pressure Switches".

5. LSCS UPSAR, Section 3.11, " Environmental Design of Mechanical and Electrical Equipment".

C. PREREQUISTTES

1. Equipment required:

a. Deadweight pump.

b. W & T pneumatic calibrator, 0-125" W.C. (accuracy: 10.5" W.C.,

minimum).

c. Static 0 Ring cover gasket, P/N 8305-096 (Stores Item #766F95).

d. Water trap.

e. Torque screwdriver, 0-12 in-lbs.

f. Test water bottles.

g. Pressure gauge 0-1500 PSIG gauge.

h. Sound Power Phone communications as follows:

1) Unit 2: 2H22-P004 (J90) and 2H13-P603 (J130).

~O DOCUMENT ID 0515I/0152A l

A-1

LIS-NB-201 R; vision 1 August 2, 1985 2

1 lO Unit 2: 2H22-P005 (J95) and 2H13-P603 (J130).

j 2) l

3) Unit 2: 2H22-P026 (J96) and 2H13-P603 (J130).

4) Unit 2: 2H22-P027 (J92) and 2H13-P603 (J130).

i D. PRECAUTIONS

1. Request permission from NSO to perform this test, have Operator verify no RPS Subchannel trip conditions exist or TIP Scans are in progress. Have Operator verify status of PCIS on ESF Panel, and '

notify NSO upon completion of this test.

2. Verify control switches S-19A and S-19C on 2H13-P609 for Outboard &

Inboard Containment Isolation Logic respectively are in the " NORM" position.

3. Verify control switches S-198 and S-19D on 2H13-P611 for Outboard &

Inboard containment Isolation Logic respectively are in the " NORM" position.

4. Verify control Switches S-79A and S79C on 2H13-P609 for Outboard &

Inboard containment Isolation Logic Respectively, are in the " NORM" position.

5. Verify Control Switches S798 and S~l9D on 2H13-P611 for Outboard &

Inboard containment Isolation Logic Respectively, are in the " NORM" position.

6. LS-2B21-N024A opens at 63.78" W.C., increasing test pressure (+12.5, decreasing actual reactor level), and will initiate the following:

a. "CHAN A-1 REACTOR AUTO SCRAM" (B203), alarm window on panel 2H13-P603.

b. "CHAN Al/81 REACTOR VESSEL LVL 3 LO" (B505), alarm window on f panel 2H13-P603.

7. LS-2821-N0245 opens .?t 63.78" W.C., increasing test pressure (+12.5, decreasing actual reactor level), and will initiate the following:

a. "CHAN B-1 REACTOR AUTO SCRAM" (B303), alarm window on panel

' ' 2H13-P603.

b. "CHAN Al/81 REACTOR VESSEL LVL 3 LO" (B505), alarm window on panel 2H13-P603.

i O

DOCUMENT ID 0515I/0152A A-2

. _ - . _ _ . . _ . _ _ _ _ _ . _ _ _ _ - _ _ - - - _ - _ - . - ~ .

LIS-NB-201 R:; vision 1 August 2, 1985 3

O

8. LS-2821-N024C opens at 63.78" W.C., increasing test pressure (+12.5" decreasing actual reactor level) and will initiate the following:

a. "CHAN A-2 REACTOR AUTO SCRAM" (B211), alarm window on panel 2H13-P603.

b. "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (B509), alarm window on l

panel 2H13-P603.

9. LS-2B21-N024D opens at 63.78" W.C., increasing test pressure (+12.5" decreasing actual reactor level) and will initiate the following:

a. "CHAN B-2 REACTOR AUTO SCRAM" (B311) alarm window on panel 2H13-P603.

b. "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (8509), alarm window on panel 2H13-P603.

10. Simultaneous opening of switches LS-2B21-N024A or LS-2B21-N024C, gg[

LS-2B21-N024B or LS-2B21-N024D will initiate a reactor scram.

11. Simultaneous opening of switches LS-2821-N024A and LS-2B21-N0245, will initiate an Outboard Primary Containment isolation.

l

12. Simultaneous opening of switches LS-2B21-N024C and LS-2821-N024D, will initiate an Inboard Primary Containment isolation.

13. Prepressurize instrument to approximately reactor pressure before returning to service.

14. Obtain the Shift Engineer's signature on Attachment A both just prior to beginning, and immediately after completing this test.

15. Instrument calibration could be affected if air is entrapped in the process sensing lines of the instrument. Ensure during performance i

of this procedure, that air does not becces entrapped in the liquid i filled sensing lines. Ensure that test tap lines are filled with liquid prior to connection of test equipment. Purge the air from either high pressure side to low pressure side or vice versa. Repeat until no air bubbles are observed, then proceed with test. Upon completion of this procedure, ensure that test. tap lines are filled with liquid after disconnection of test equipment and prior to l

j installation of the test tap plugs or caps, to ensure no air may be

! entrapped. Wipe up any liquid that may have been spilled in accordance with routine Rad /Ct.am procedures.

l I l

DOCUMENT ID 0515I/0152A A-3

/

LIS-NB-201 R: vision 1 August 2, 1985 4

O E. kIMITATIONS AND ACTIOnlS

1. This procedure's instructions take precedence, but they may be supplemented by manufacturer's instructions at the discretion of Supervisory personnel.

2. Frequency of Surveillance Test:

a. Calibration is required at least once per 18 months (550 days).

3. During procedure, inspect instrument for any signs of wear or physical damage.

4. Upon completion of this test, file the completed Attachments A & B in the Instrument Department, and report the test completion date on the

" Monthly" Test Assignment Schedule.

5. Completo Valve checkoff Sheet (Attachment B), for each instrument prior to, and ismediately af ter performing this surveillance.

6. Verify completion of each step which requires recording by initials l

and date (unless directed in the procedure to record specific information).

' '1. Supervisory approval must be obtained prior to making any adjustments. Supervisor should initial adjacent to data sheet out of tolerance "As Found" values as his approval for adjustment.

8. The calibration of this instrument is based on the following assumptions:

a. Vessel Pressure 1000 psig.

b. Vessel Temperature - SAT.

c. Drywell Temperature 135'F.

d. Containment temperature 80*F.

e. Temperature at calibration ~10*F.

f. Carry-under not considered.

I

g. Velocity Head correction not considered. Appropriate density I corrections have been made. l 4

O DOCUIENT ID 0515I/0152A A-4 l i

_ . _ . _ _ _ _ _ . _ _ . - _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ - _ . . _ _ - - _ _ . _ . . _ ~ - . . . _ . _ _ . _ , , _ _ . _ _ . . _

LIS-NB-201 R1 vision 1 August 2, 1985 5

O F. P_ROCEDURE CAUTION Lines are normally at reactor pressure, remove vent caps with caution.

- Any water is to be considered contaminated, follow appropriate '

Rad / Chem procedures.

l

1. ISOLATE Level Switch LS-2B21-N024A, and RECORD on Unit 2 Reactor Vessel Low Water Level Scram and Primary Containment Isolation Calibration Data Sheet (Attachment A). ,

2. CONNECT water test bottles and trap to high and low pressure test connections.

3. CONNECT the pneumatic calibrator to instrument high pressure connection. (stamped "H" on switch body).

l M9IEE

[1] In order to reestablish the normal operating parameter for the process sensing instrument under test, after connection of the

' test equipment, apply pressure as required to cycle the instrument thru it's full adjustable range, one to two times -

prior to obtaining "As Found" set and reset values for the i

instrument switch.

[2] After cycling switch, request operator to reset sub-channel scram logic using Reactor Scram Roset Control Switch, SS, on i

panel 2H13-P603. Have Operator reset Inboard and Outboard Isolation logic using Isolation Logic Roset Pushbuttons, S-32 and S-33, on panel 2H13-P601.

! 4. APPLY test pressure as per Attac.hment A. RECORD "As Found" switch l

setpoint and reset point on Attachment A.

NEIEE

[1] When alarm window "CHAN A-1 REACTOR AUTO SCRAM" (8203), on panel 2H13-P603, initiates, RECORD set "As Found" on Attachment A.

[2] When alarm window goes to slow flashing on decreasing pressure, RECOND reset "As Found" on Attachment A.

5. VERIFY alarm windows "CHAN A-1 REACTOR AUTO SCRAM" (8203), and "CHAN Al/B1 REACTOR VESSEL LVL 3 LO" (B505), have initiated on panel 2H13-P603. RECORD on Attachment A.

O DOCUMENT ID 0515I/0152A l

l A-5

LIS-NB-201 Revision 1 August 2, 1985 O

6. If "As Found" data is within allowable tolerance, RECORD "As Left" on Attachment A.

7. If "As Found" data is not within allowable tolerance, ADJUST as required, and RECORD "As Left" on Attachment A.

8. REDUCE the test pressure to zero.

t

9. Have Operator RESET reactor sub-channel scram logic using Reactor Scram Reset Control Switch, S5, on panel 2H13-P603, and RECORD on Attachment A.

10. Have Operator RESET isolation logic by momentarily DEPRESSING Inboard and Outboard Isolation Logic Roset Pushbuttons, S-32 and S-33, respectively, on panel st13-P601. RECORD on Attachment A.

11. DISCONNECT the pneumatic calibrator, water bottles and trap.

12. If prepressurization is D91 required, CLOSE the high and low pressure test connection vent valves and ENSURE the lines are capped (plugged).

13. If prepressurization la required, PERFORM the following steps

a. CONNECT the deadweight pump and 0-1500 PSIG pressure gauge to the high pressure test connection.

b. CLOSE the low pressure test connection vent valve and ENSURE the line is capped (plugged).

c. OPEN the instrument equalizing valve.

d. PREPRESSURIZE the switch to approximately reactor pressure.

e. CLOSE the high pressure test connection vent valve.

f. DISCONNECT the deadweight pump and gauge from the high pressure test connection.

g. ENSURE the high pressure test line is capped (plugged).

_ NOTE Whenever a Static 0 Ring Pressure Switch cover is removed, the cover gasket must be replaced and the cover torqued down. If the cover was l

991 removed, record "N/A" on line 10, of Attachment A and proceed on with the procedure. If the cover wgg removed, perform the following steps:

O DOCUMENT ID 05151/0152A l

l A-6

i LIS-NB-201 R:; vision 1 August 2, 1985 7

O I Complete a Material Request Form for the gasket (see l a.

Prerequisite C.l.c for Static 0 Ring part number or Ceco Stores Item number).

b. Remove the old cover gasket and clean sealing areas with alcohol, if necessary,

c. Install the new gasket onto the pressure switch body.

4

d. Reinstall the cover and torque the coverscrews until the gasket is uniformly compressed.

e. Have the reinstallation I.M. Technician initia4 and date line 10, of Attachment A.

' f. Attach any gasket red tags to Attachment A.

i 14. RETURN LS-2B21-N024A to service and RECORD on Attachment A.

I 15. VERIFY alarm window "CHAN A-1 REACTOR AUTO SCRAM" (8203), is reset on panel 2H13-P603, and RECORD on Attachment A.

I

16. VERIFY alarm window "CHAN Al/B1 REACTOR VESSEL LVL 3 LO" (8505), is +

reset on panel 2H13-P603, and RECORD on Attachment A.

17. ISOLATE Level Switch, LS-2B21-N0248, and RECORD on Unit 2 Reactor Vessel Low Water Level Scram and Primary Containment Isolation Calibration Data Sheet (Attachment A).

18. CONNECT water test bottles and trap to high and low pressure test f

connections.

i

19. CONNECT the pneumatic calibrator to instrument high pressure connection. (stamped "H" on switch body).

HOIEE

[1] In order to reestablish the normal operating parameter for the process sensing instrument under test, after connection of the test equipment, apply pressure as required to cycle the instrument thru it's full adjustable range, one to two times prior to obtaining "As Found" set and reset values for the

! instrtament switch.

l

[2] After cycling switch, request operator to reset sub-channel scram logic using Reactor Scram Reset Control switch, SS, on -

panel 2H13-P603. Have Operator reset Inboard and Outboard Isolation logic using Isolation Logic Roset Pushbuttons, S-32 and S-33, on panel 2H13-P601.

! DOCUMENT ID 0515I/0152A r

A-7 l .

LIS-N8-201 Rr, vision 1 August 2, 1985 8

O APPLY test pressure as per Attachment A. RECORD "As Found" switch 20.

setpoint and reset point on Attachment A.

NOTES (1) When alarm window "CHAN B-1 REACTOR AUTO SCRAM" (B303), on panel 2H13-P603, initiates, RECORD set "As Found" on Attachmer.t A.

[2] When alarm window goes to slow flashing on decreasing pressure, RECORD reset "As Found" on Attachment A.

21. VERIFY alarm windows "CHAN B-1 REACTOR AUTO SCRAM" (B303), and "CHAN l'

A1/B1 REACTOR VESSEL LVL 3 LO" (5505), have initiated on panet l i 2H13-P603. RECORD on Attachment A.

22. If "As Found" data is within allowable tolerance, RECORD "As Left" on i l

Attachment A.

23. If "As Found" data is not within allowable tolerance, ADJUST as I required, and RECORD "As Left" on Attachment A.

24. REDUCE the test pressure to zero.

25. Have Operator RESET reactor sub-channel scram logic using Reactor hv Scram Reset Control Switch, S5, on panel 2H13-P603, and RECORD on Attachment A.

26. Have Operator RESET isolation logic by momentarily DEPRESSING Inboard and Outboard Isolation Logic Roset Pushbuttons, S-32 and S-33, respectively, on panel 2H13-P601. RECORD on Attachment A.

27. DISCONNECT the pneumatic calibrator, water bottles and trap.

28. If prepressurization is D9.t,trequired, CLOSE the high and low pressure test connection vent valves and ENSURE the lines are capped (plugged).

29. If prepressurization 13, required PERFORM the following steps:

a. CONNECT the deadweight pump and 0-1500 PSIG pressure gauge to the high pressure test connection.

b. CLOSE the low pressure test connection vent valve and ENSURR the line is capped (plugged),

c. OPEN the instrtasent equalizing valve.

j d. PREFRESSURIZE the switch to approximately reactor pressure.

O DOCUMENT ID 0515I/0152A A-8 1

LIS-NS-201 Rsvision 1 August 2, 1985 9

e 2 e. CLOSE the high pressure test connection vent valve.

f.

DISCONNECT the deadweight pump and gauge from the high pressure j l

test connection.

q'

g. ENSURE the high pressure test line is capped (plugged),

a y l

Whenever a Static 0 Ring Pressure Switch cover is removed, the cover gasket must be replaced and the cover torqued down. If the cover m D91 removed, record "N/A" on line 22, of Attachment A and proceed on with the procedure. If the cover wgg, removed, perform the following steps:

a. Complete a Material Request Form for the gasket (see Prerequisite C.l.c for Static 0 Ring part number or Ceco Stores Item number).

b. Remove the old cover gasket and clean sealing areas with I alcohol, if necessary.

7

c. Install the new gasket onto the pressure switch body.

O d. Reinstall the cover and torque the coverscrews until the gasket is uniformly compressed.

e. Have the reinstallation I.M. Technician initial and date line 22, of Attachment A.

f. Attach any gasket red tags to Attachment A.

30. RETURN LS-2B21-N0245 to service and RECORD on Attachment A.

1 I 31. VERIFY alarm window "CHAN B-1 REACTOR AUTO SCRAM" (8303), is reset on i panel 2H13-P603, and RECORD on Attachment A.

32. VERIFY alarm window "CHAN A1/B1 NEACTOR VESSEL LVL 3 Lo" (8505), is reset on panel 2H13-P603, and RECORD on Attachment A.

1 i

33. ISOLATE Level Switch, LS-2B21-N024C, and RECORD on Unit 2 Reactor Vessel Low water Level Scram and Primary Containment Isolation Calibration Data Sheet (Attachment A).

34. CONNECT water test bottles and trap to high and low pressure test connections.

l

35. CONNECT the pneumatic calibrator to instrument high pressure connection. (stamped "H" on switch body).

l DOCUMENT ID 05151/0152A A-9

LIS-NB-201 R vicion 1 August 2, 1985 10 0

=

[1] In order to reestablish the normal operating parameter for the process sensing instrument under test, after connection of the test equipment, apply pressure as required to cycle the instrument thru it's full adjustable range, one to two times prior to obtaining "As Found" set and reset values for the instrusant switch.

[2] After cycling switch, request operator to reset sub-channel scram logic using Reactor Scram Roset control Switch, 55, on panel 2H13-P603. Have Operator reset Inboard and Outboard Isolation logic using Isolation Logic Reset Pushbuttons, S-32 and S-33, on panel 2H13-P601.

36. APPLY test pressure as per Attachment A. RECORD "As Found" switch setpoint and reset point cn Attachment A.

NOT!M

[1] When aldra window "CHAN A-2 REACTOR AUTO SCRAM" (B211), on panel 2H13-P603, initiates, RECORD set "As Found" on Attachment A.

[2] When alarm window goes to slow flashing on decreasing pressure, RECORD reset "As Found" on Attachment A.

1 3*l . VERIFY alarm windows "CHAN A-2 REACTOR AUTO SCRAM" (B211), and "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (B509), have initiated on panel 2H13-P603. RECORD on Attachment A.

38. If "As Found" data is within allowable tolerance, RECORD "As Left" on Attachment A.

39. If "As Found" data is not within allowable tolerance, ADJUST as ,

. required, and RECORD "As Left" on Attachment A.

40. REDUCE the test pressure to zero. l 4

41. Have Operator RESET reactor sub-channel scram logic using Reactor Scram Roset Control Switch, S5, on panel 2H13-P603, and RECORD on Attachment A.

42. Have Operator RESET isolation logic by momentarily DEPRESSING Inboard and Outboard Isolation Logic Reset Pushbuttons, S-32 and S-33, respectively, on panel 2H13-P601. seenen on Attachment A.

43. DISCONNECT the pneumatic calibrator, water bottles and trap.

O DOCUMENT ID 0515I/0152A A-10

LIS-NB-201 R; vision 1 August 2, 1985 11 0 1 If prepressurization is not required, CLOSE the high and low pressure

44. l test connection vent valves and ENSURE the lines are capped (plugged).

45. If prepressurization is required, PERPORM the following steps:

a. CONNECT the deadweight pump and 0-1500 PSIG pressure gauge to the high pressure test connection.

b. CLOSE the low pressure test connection vent valve and ENSURE the line is capped (plugged).

c. OPEN the instrument equalizing valve.

d. PREPRESSURIZE the switch to approximately reactor pressure.

e. CLOSE the high pressure test connection vent valve.

f. DISCONNECT the deadweight pump and gauge from the high pressure test connection,

g. ENSURE the high pressure test line is capped (plugged).

~

O Whenever a Static 0 Ring Pressure Switch cover is removed, the cover gasket must be replaced and the cover torqued down. If the cover was not removed, record "N/A" on-line 34, of Attachment A and proceed on with the procedure. If the cover was removed, perform the following steps:

a. Ceeplete a Material Request Form for the gasket (see prerequisite C.l.c for Static 0 Ring part number or Ceco Stores Item number).

b. Remove the old cover gasket and clean sealing areas with alcohol, if necessary.

c. Install the new gasket onto the pressure switch body.

d. Reinstall the cover and torque the coverscrews until the gasket is uniformly compressed.

e. Have the reinstallation I.M. Technician initial and date line 34, of Attachment A.

E. Attach any gasket red tags to Attachment A.

46. RETURN LS-2B21-N024C to service and RECORD on Attachment A.

O DOCUMENT ID 0515I/0152A A-ll

' LIS-NB-201 R:; vision 1 August 2, 1985 12 O

47. VERIFY alarm window "CHAN A-2 REACTOR AUTO SCRAM" (B211), is reset on panel 2H13-P603. and RECORD on Attachment A. l l

j

48. VERIFY alarm window "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (B509), is reset on panel 2H13-P603, and RECORD on Attachment A.

49. ISOLATE Level Switch, LS-2B21-N024D, and RECORD on Unit 2 Reactor Vessel _ Low Water Level Scram and Primary Containment Isolation ,

Calibration Data Sheet (Attachment A).

50. CONNECT water test bottles and trap to high and low pressure test connections.

5L. CONNECT the pneumatic calibrator to instrument high pressure connection. (stamped "H" on switch body).

NOTES

[1] In order to reestablish the normal operating parameter for the process sensing instrument under test, after connection of the test equipment, apply pressure as required to cycle the instrument thru it's full adjustable range, one to two times prior to obtaining "ns Found" set and reset values for the instrianent switch.

[2] After cycling switch, request operator to reset sub-channel scram logic,using Reactor Scram Reset Control Switch, 35, on panel 2H13-P603. Have Operator reset Inboard and Outboard Isolation logic using Isolation Logic Reset Pushbuttons, S-32 and S-33, on panel 2H13-P601.

52. APPLY test pressure as per Attachment A. RECORD "As Found" switch setpoint and reset point on Attachment A. -

NOT33

[1] When alarm window "CHAN B-2 REACTOR AUTO SCRAM" (B311), on panel 2H13-P603, initiates, RECORD set "As Found" on Attachment A.

[2] When alarm window goes to slow flashing on decreasing pressure, RECOND reset "As Found" on Attachment A.

53. VERIFY alarm windows "CHAN B-2 REACTOR AUTO SCRAM" (B311), and "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (8509), have initiated on panel 2H13-P603. RECORD on Attachment A.

54. If "As Found" data is within allowable tolerance, RECORD "As Left" on Attachment A.

l O

DOCUMENT ID 05151/0152A A-12

LIS-Nu-201 R* vision 1 August 2, 1985 13 i

O i

55. If "As Found" data is not within allowable tolerance, ADJUST as l 1

required, and RECORD "As Left" on Attachment A. I

56. REDUCE the test pressure to zero.

j 5~7 . Have Operator RESBT reactor sub-channel scram logic using Reactor Scram Reset Control Switch, S5, on panel 2H13-P603, and RECORD on I Attachment A.

58. Have Operator RESET isolation logic by momentarily DEPRESSING Inboard and Outboard Isolation Logic Reset Pushbuttons, S-32 and S-33, respectively, on panel 2H13-P601. RECORD on Attachment A.

59. DISCONNECT the pneumatic calibrator, water bottles and trap.

I

60. If propressurization is D93. required CLOSE the high and low pressure test connection vent valves and ENSURE the lines are capped (plugged).

61. L( propressurization 13, required, PERFORM the following steps:

a. CONNECT the deadweight pump and 0-1500 PSIG pressure gauge to the high pressure test connection.

CLOSE the low pressure test connection vent valve and EMSURR the O b.

line is cepped (plugged).

OPEN the instrument equalizing valve.

~

c.

! d. PREPRESSURIZE the switch to approximately reactor pressure.

e. CLOSE the high pressure test connection vent valve.

f. DISCONNECT the deadweight pump and gauge from the high pressure test connection.

g. ENSURE the high pressure test line is capped (plugged).

O

.M._.TE.

Whenever a Static 0 Ring Pressure Switch cover is removed, the cover gasket mast be replaced and the cover torqued down. If the cover weg.

Del removed, record "N/A" on line 46, of Attachment A and proceed on with the procedure. If the cover'wgg. removed, perform the following steps: ,

a. Complete a Material Request Form for the gasket (see Prerequisite C.1.c for Static 0' Ring part number or CECO Stores Item number). j l

O !

l DOCUMENT ID 0515I/0152A n ,

j i

A-13 l

LIS-NB-201 i Rsvision 1 l August 2, 1985 I 14 O

Remove the old cover gasket and clean sealing areas with l b.

alcohol, if necessary.

c. Install the new gasket onto the pressure switch body.

d. Reinstall the cover and torque the coverscrews until the gasket is uniformly compressed.

e. Have the reinsta11ation I.M. Technician initial and date line 46, of Attachment A.

f. Attach any gasket red tags to Attachment A.

62. RETURN LS-2B21-N024D to service and RECORD on Attachment A.

63. VERIFY alarm window " CHAM B-2 REACTOR AUTO SCRAM" (B311), is reset on panel 2H13-P603, and RECORD on Attachment A.

64. VERIFY alarm window " CHAM A2/B2 REACTOR VESSEL LVL 3 LO" (B509), is reset on panel 2H13-P603, and RECORD on Attachment A.

G. CHECKLISTS

1. None.

H. E LECHNICAL SPECIFICATION REFERENCES

1. Paragraph 4.3.1.1.

2. Table 4.3.1.1-1.

3. Table 2 2.1-1.

4. Paragraph 4.3.2.1.

5. Table 4.3.2.1-1.

6. Table 3.3.2-2.

f O

DOCUMENT ID 05151/0152A 3

A-14

LIS-NB-201 R;vicion 1 August 2, 1985 15 O

ATTACHMENT A Unit 2 Reactor Vessel Low Water Level Scram and Primary Containment Isolation Calibration Data Sheet

1. Shift Engineer authorization to start:

Level Switch: LS-2B21-N024A Location: 2H22-P004

2. Date tested:

3. (Step F.1) LS-2B21-N024A isolated:

/

4. (Step F.4) LS-2B21-N024A, "As Found" set / reset:

Desired setpoint: open at 63.15" W.C. , increasing (62.51 to 63.78" W.C. )

Tech spec. LCO: 64.84" W.C.

l

&ctual Reactor Level values Desired setpoint: open at +13.4", decreasing (+12.5 to +14.3")

Tech Spec. LOO: +11"

5. (Step F.5) "CHAN A-1 REACTOR AUTO SCRAM" (B203), initiated on 2H13-P603:

6. (Step F.5) "CHAN Al/B1 REACTOR VESSEL LVL 3 LO" (B505),

initiated on 2H13-P603:

/

7. (Step F.6 or 7) LS-2B21-N024A "As Left" set / reset:

Desired setpoint: open at 63.15" W.C. , increasing (62.51 to 63.78" W.C.)

Tech Spec. Loo: 64.84" W.C.

Actual Reactor Level values Desired setpoint: open at +13.4", decreasing (+12.5 to +14.3")

Tech Spec. LCO: +11" l 8. (Step F.9) Reactor sub-channel scram logic reset:

t

9. (Step F.10) Inboard and Outboard Isolation logic reset: ,

10. I.M. Technician verification of proper gasket replacement:

11. (Step F.14) LS-2B21-N024A returned to service:

12. (Step F.15) "CHAN A-1 REACTOR AUTO SCRAM" (B203), reset on 2H13-P603:

O DOCUMENT ID 0515I/0152A A-15 l

LIS-NB-201 R. vision 1 August 2, 1985 16 O

13. (Step P.16) "CHAN Al/B1 REACTOR VESSEL LVL 3 LO" (B505),

reset on 2H13-P603:

Level Switch: LS-2821-N0248

' ~ -

ua - 2H22-P02*7 -

14. Date tested:

15. (Step F.17) LS-2B21-N0248 isolated:

/

16. (Step F.20) LS-2B21-N0248, "As Found" set / reset:

Desired setpoint: open at 63.15" W.C., increasing (62.51 to 63.78" w.C.)

Tech Spec. LCO: 64.84" W.C.

Actual Reactor Level values Desired setpoint: open at +13.4", decreasing (+12.5 to +14.3")

Tech Spec. LCO: +11"

17. (Step F.21) "CHAN B-1 REACTOR AUTO SCRAM" (B303), initiated on 2H13-P603:

18. (Step F.21) "CHAN Al/B1 REACTOR VESSEL LVL 3 LO" (8505),

initiated on 2H13-P603: _

/

19. (Step F.22 or 23) LS-2B21-N024B "As Left" set / reset: __

Desired setpoint: open at 63.15" W.C., increasing (62.51 to 63.78" W.C.)

Tech Spec. LCO: 64.84" W.C.

1 Actual Reactor Level values Desired setpoint: open at +13.4", decreasing (+12.5 to +14.3")

Tech Spec. LCO: +11"

20. (Step F.25) Reactor sub-channel scram logic reset:

21. (Step F.26) Inboard and Outboard Isolation logic reset:

22. I.M. Technician verification of proper gasket replacement:

23. (Step F.30) LS-2B21-N0248 returned to service: _._

24. (Step F.31) "CHAN B-1 REACTOR AUTO SCRAM" (B303), reset I on 2H13-P603:

O DOCUMENT ID 0515I/0152A A-16

LIS-NB-201 l R;vialon 1 August 2, 1985 17 O

25. (Step F.32) "CHAN Al/B1 REACTOR VESSEL LVL 3 LO" (8505),

reset on 2H13-P603:

Level Switch: LS-2B21-N024C Location; 2H22-P005

26. Date tested:

27. (Step F.33) LS-2B21-N024C isolated: )

/

28. (Step F.36) LS-2B21-N024C, "As Found" set / reset:

Desired setpoint: open at 63.15" W.C., increasing (62.51 to 63.78" W.C.)

Tech Spec. LCO: 64.84" W.C.

Actual Reactor Level values Desired setpoint: open at +13.4", decreasing (+12.5 to +14.3")

Tech Spec. LCO: +11" i

29. (Step F.37) "CHAN A-2 REACTOR AUTO SCRAM" (B211), initiated on 2H13-P603:

30. (Step F.37) "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (B509),

initiated on 2H13-P603:

/

31. (Step F.38 or 39) LS-2B21-N024C "As Left" set / reset:

Desired setpoint: oten at 63.15" W.C., increasing (62.51 to 63.78" W.C.)

Tech Spec. LCO: 64.84" W.C.

Actual Reactor Level values Desired setpoint: open at +13.4", decreasing (+12.5 to +14.3")

Tech Spec. LCO: +11"

32. (Step F.41) Reactor sub-channel scram logic reset:

33. (Step F.42) Inboard and Outboard Isolation logic reset:

34. I.M. Technician verification of proper gasket replacement:

35. (Step F.46) LS-2B21-N024C returned to service:

36. (Step F.47) "CHAN A-2 REACTOR AUTO SCRAM" (B211), reset on 2H13-P603:

l

37. (Step F.48) "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (B509), '

reset on 2H13-P603:

O DOCUMENT ID 0515I/0152A A-17

LIS-NB-201 Rsvicion 1 August 2, 1985 l 18 O l Level Switch: LS-2B21-N024D l Location: 2H22-P026

}

38. Date tested:

39. (Step F.49) Ls-2B21-WG24D isolated: _

/

40. (Step F.52) LS-2B21-N024D, "As Found" set / reset:

Desired setpoint: open at 63.15" W.C., increasing (62.51 to $3.78" W.C.)

Tech Spec. LCO: 64.84" W.C.

Actual Reactor Level values Desired setpoint: open at +13.4", decreasing (+12.5 to +14.3")

Tech Spec. LCO: +11"

41. (Step F.53) " CHAM B-2 REACTOR AUTO SCRAM" (B311), initiated on 2H13-P603:

42. (Step F.53) "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (B509),

initiated on 2H13-P603:

/

43. (Step F.54 or 55) LS-2B21-N024D "As Left" set / reset: ___

Desired setpoint: open at 63.15" W.C., increasing (62.51 to 63.78" W.C.)

O~ Tech Spec. LCO: 64.84" W.C.

Actual Reactor Level values Desired setpoint: open at +13.4", decreasing (+12.5 to +14.3")

Tech Spec. LCO: +11"

44. (Step F.57) Reactor sub-channel scram logic reset:

45. (Step F.58) Inboard and Outboard Isolation logic reset:

46. I.M. Technician verification of proper gasket replacement:

47. (Step F.62) LS-2821-N024D returned to service: o

48. (Step F.63) "CHAN B-2 REACTOR AUTO SCRAM" (B311), reset I on 2H13-P603:

49. (Step F.64) "CHAN A2/B2 REACTOR VESSEL LVL 3 LO" (B509),

reset on 2H13-P603:

50. Shif t Engineer acknowledgement of surveillance finish: . .

51. I.M. Technician (s):

' O' DOCUMENT ID 0515I/0152A :

A-18

n.

LIS-NB-201 1 R, vision 1 August 2, 1985 19 i

O

52. Test equipment:

a. Deadweight pump I.D. #: , accuracy: n/a

, accuracy: " W.C.

b. Pneumatic Calibrator I.D. 8: , accuracy: n/a

c. Torque screwdriver I.D. #:

Pressure gauga I.D. 3: , accuracy: n/a d.

\

53. I.M. Supervisor approval /date:

54. I.M. Supervisor verification that the I.M. Surveillance coordinator is notified that performance of this surveillance satisfies the monthly requirement for the Functional Test, LIS-NB-401:

O O

DOCUMENT ID 0515I/0152A A-19 .

O O i O t

LIS-NB-201 -

DATE:

ATTACHMENT 5 INSTRLIMENT VALVE CHECK 0FF SilEET FOR

[*9fd 2, 985 ,

SEAL PRE 55 No. 2a !

L S -2 B 21 - N 0 2+A SEAL PRESS WORKWN DIECK Wofu(MMI DIECX

PosTion As rouNb" SEN. PRESS WORKMM (NECM "A5 LEFT

tilNBER (IMilAI./ BATE) (INITIAL /DATE) i (OPKl.) IWMBER (INITIAL /DATE) (GP/CL)

VALVE l

INSTMDMENT H .

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i LIS-NB-201 DATE:

ATTACHMENT 5 " "

INSTRUMENT VALVE CHECK 0FF SHEET FOR SEAL PRESS No.

L S -2B 21 - N 0 2+B $f"" '

l l

i, SEAL PRESS WCHKMAN (NECK WORKMAN (NELK POSITION *AS FOUND* SEAL PRESS WORKMAN 04ECK "A5 LE FT

NUMBER (OP/CL) NUMBER (IMTIAL/b4TE) (INITIAL /DATE) [

! VALVE- (OPEG (INITIAL / BATE) I INSTMDMENT H RACE R00TST8P L INSTRUMENT H u STOP L '

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l ATTACHMENT 5 Uh.-NB-201 DATE:

INSTRUMENT VALVE CHECK 0FF SHEET FOR ^ 9ust 2, 1985 SEAL PRE 55 No.

L S-2 B 21 - N O 2 +C

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WolB(MAN OlECM WORKMAN CNECM P99 TION *AS FOUND* SEAL PRESS WORKMAN DIECM "A5 LEFT' SEAT PRESS (OP/CL) NUMBER (IMTIAL/DATE) (INITIAL /DATE)

VALVE, (OPEL) NUMBER (INITIAL /DATE)

INSTRUMENT H :

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STOP L

d INSTRUMENT ;

EaunuzER InsTRuuCNT H I VENT L INSTRUMENT H ORAIN (TCP) L

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LIS-NB-201 ATTACHMENT 5 "'#"

i DATE: .

! INSTRUMENT VALVE CHECK 0Fi SHEET FOR August 2, 1985 t SEAL PRESS No.

L S-2B 21 - N 0 2+D 23 (FINAL)

SEAL PRESS WolKkM UIECK WDRNMMa uiELK MSITION "As FOUND* SEAL PRESS WORKMAN 0lECN "A5 LEFT" (OP/CL) NUMBER (IMTIAL/b4TE) (INITIAL /DATE) l VALVE (OPEL) NUMBER (INITIAL / TATE) i i INSTRIMENT H RACR ROOTST8P L I'.

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O Appendix B Reference Material Provided by GPU Nuclear SARGENT& LUNDY O

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U.S. Nuclear Regulatory Comission ,

Document Control Desk l I

Washington, DC 20555 l

Dear Sir:

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Subject:

Oyster Creek Nuclear Generating Station j Docket No. 50-219 l Licensee Event Report This letter forwards one (1) copy of Licensee Event Report (LER)

Very truly yours,

&%% LAu Petii v. riedler Vice President and Director PBF:JJR: dam (0174A)

Enclosures cc: Dr. Thomas E. Murley, Administrator l

Region I U.S. Nuclear Regulatory Comission 631 Park Avenue King of Prussia, PA 19406 g Mr. Jack N. Denchew, Jr.

U.S. Nuclear Regulatory Congnission

7920 Norfolk Avenue. Phillips B1dg.

Bethesda, MD 20014 ~

Mail Stop No. 314

NRC Resident Inspector O Oyster Creek Nuclear Generating Station Forked River, W 08731 B-1

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A plant shutdown was conducted on March 27, 1986, due to repeatability /drif t problems with Reactor Low Water Level Scram switches. Tne suspect Reactor Low Water Level Scram switches (SOR, " Static-0-Ring", model 103ASB212NXJJTTX6) were installed during the Oyster Creek Environmental Qualification ~ outage in l October / November 1985. Performance of monthly surveillances revealed setpoint l drift problems. Increased surveillance frequency did not resolve the setpoint l drift / repeatability problem. Evaluation of the accumulated calibration data, and i discussions with technical representatiyes of SOR, concluded that the switches l were not meeting their design specifications, and that the magnitude and direction of future drifting was uncertain. It was also determined that the failure mechanism was not known. A plant shutdown was initiated and the Reactor Low Water Level SOR switches were replaced with a different model SOR switen.

THe replacement model (103ASB8212NXJJTTX6) it. the same model number as four

~

s.iitches installed in the No'vember 1985 outage for the Reactor Low Low Water Level switches which have perfonned satisfactorily. ReactorstartuDas commenced on March 30, 1986.

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0 l o 012 o' 016 DATE OF OCCURRENCE The date of occurrence was March 27, 1986.

IDENTIFICATION OF OCCURRENCE A plant shutdown was required by plant Technical Specifications, when all four Reactor Low Water Level Scram sensors were declared inoperable due to repeatability and drift problems. This event is reportable under 10CFR50.73.a.(2).i.A.

CONDITIONS PRIOR TO OCCURRENCE I

)

At the time of occurrence, the reactor was operating at a themal power of 1800 MWt (93%) and the mode switch was in RUN. .

V DESCRIPTION OF OCCURRENCE

1) History of RE05s (Reactor Cow Water Level Scram Switches)-

During the Environmental Qualification (EQ) outage in October / November 1985, the four Reactor Low Water Level Scram switches (Yarway) were replaced with SOR (Static-0-Ring model 103ASB212NXJJTTX6) environmentally qualified switches.

Calibrations were performed monthly in accordance with the Master Surveillance Schedule. On January 17, 1986, significant drift was observed on switches RE05A1 and RE05/19A1 (LER 86-001). An additional calibration (on RE05A1 and RE05/19A1) was perfonned on January 20, 1986, and though both instrmeent setpoints were satisfactory, the RE05A1 switch failed when being valved back into service. The switch was replaced. The spare switch was bench tested prior to installation to ensure repeatability. Following installation the switch was calibrated and .

placed into service.

On February 20,1986, RE05A1 and RE0581 drifted significantly. The switches were reset and an additional calibration was scheduled for February 27,1986 to detect drift over a one week period. The RE05A1 sensor was again out of specification on February 27, 1986 and was replaced. l A successful surveillance was run on March 6,1986 on all four sensors. l Based on the satisfactory result of the test, the next surveillance was scheduled

I I for March 24, 1986.

On March 24, 1986,- the first sensor surveilled (RE05/19A1) showed abnonsal )

behavior. Without any switch adjustments, three significantly different trip i

V points were obtained. The surveillance was teminated when the switch was i declared inoperable and replaced. ,

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LICENSEE EVENT REPORT (tERI TEXT CONTINUATION " ~ " **'**

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mna ., ,. m ., - c w man.nn On Maren 25, 1986 discussions were held witn SOR representatives, and a switch replacement criteria was developed (see Item 3). Tne surveillance was continued with the performance of the next two switches found to be acceptable.

On March 26, 1986, the fourth switen (RE05A1) was tested. It failed the switch replacement criteria and was replaced.

On the merning of March 27, 1986, a Plant Review Group (PRG) meeting was called to evalcate the performance nistory of the 50R Reactor Low Water Level sensors. Based on input from ongoing investigations by Plant Engineering, Technical Functions Engineering, and 50R (see Item 4) the PRG concluded that:

1. The magnitude and direction of setpoint drift is unpredictable.

2. The drif t cannot be shown to be time dependent.

3. The failure mechanism is unknown.

4. The. SOR Reactor Water Low Low Level switches had demonstrated satisfactory perfomance.

Based on the above conclusions, the sensors were judged to be unreliable and a

' p plant shutdown was conducted to allow replacement of tne four (4) REOS switches with the same model switch in use for the RE02 Low Low Level switches.

2) History of RE02s (Reactor Low Low Water Level Switches) -

During the Environmental Qualification outage in October / November of 1985, the existing four Reactor Low Low Water Level switches (Yarvay) were replaced with SOR (model 103ASBB212NXJJTTX6) environmentally qualified switches. The RE02s and RE05s are m7o ntee on instrument racks RK01 and RK02. (Two RE02s and two RE05s are on each rack and have coainon reference and variable legs.) After startup from tne outage, calibrations were perforined monthly in accordance with the Master Surveillance Schedule. One significant drift was observed in the RE02 data. On January 11,1986, RE02C setpoint was found significantly out of specifications, the setpoint was adjusted, and the switen was returned to service, and has performed acceptably in subsequent tests.

3) REOS Switch replacement criteria - ;

On March 25, 1966, discussions were held witn $0R representatives to determine what the maximum amount of setpoint drift the 50R switches should-have, The vendor reaffimed that the $ Witch setpoint should not drift more than 1

(No data on setpoint drift is provided in the 1" between monthly) vendor literature. calibrations.An allowance for calibration gauge error and performa error was added to the 1" drif t allowance. The resulting switch replacement criteria was: The as-found value must be + 1.4" of the previous adjusted as-lef t

~

I I setpoint.

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4) Investigations into -05 Problems -

l Three dif ferences were . hntified between the RE02 Low Low Water Level switches and the REOS Low Water Level switches:

a) Low level REOS is model 103ASB212NXJJTTX6 Low Low Level RE02 is mcdel 1UJA588212NXJJTTX6 The difference is REOS has a one Micro switch, and RE02 has two micro switches.

b) Low level RE05 switch's were not installed the same as the Low Low RE02 level switches.

The Low Low level REL2 switches were installed in accordance with vendor recomendations: Process lines to bottom taps, and vents to top taps.

The Low level RE05 switches were installed with the process if nes and tne vent lines connected to the top taps of the instrument. This j

configuration had been approved tnrough tne design change control process.

The low level switch tubing configuration made air elimination C\ di f ficul t. Nomal instrument fill techniques minimize the amount of air V entrapped in the switch tnus minimizing the effect on the switen p setpoint. It is not believed that the tubing configuration had a significant contricution to the repeatability prooles.

c) Low Level REOS setpoint is $8.9+1" WC Low Low Level RE02 setpoint is T3.5+1.5" WC To ensure that the RE02 model would~ perform well at the lower setpoint, an extensive bench calf oration program was performed on the six replacement switches. The program included repetitive calibrations followed by pressurization to_ operating conditions ( 1020 psig static pressure) for 'a minimum of one hour, and then another set of calibrations. ?fftFGele was~pe~rformed at least five times on each swi tch. One switch of the six failed the bench test early in the tast program, due to deadband problems.

APPARENT CAUSE OF OCCURRENCE The RE05A1 sensor was removed from service on January 20,1986 (after falling to reset after being valved in.) was examined by SOR and no failure mechanism was -

identified.

The RE05A1 sensor removed from service on February 27, 1986 was examined by 50R. Deposits were found in the diaphragm area and rust was found on one switch mechanism bearing.

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q 0l 7 CP Oyster Creek, Unit 1 o is to lo lo 1211 l 9 81 6 -- -- 010 01 5 OE we ,. . . e -., i m 50R is continuing to investigate tne problem and presently has a test program in progress. A follow up report to LER 86-001 will adcress tne results of the SOR testing program.

ANALYSIS OF OCCURRENCE AND SAFETY ASSESSMENT The low reactor vessel level scram is designed to prevent continued reactor operation with steam carry-under from the reactor vessel steam separators. Steam carry-under is a condition wnich results from uncovering the bottom of the steam separators allowing steam to be drawn into tne downcomer region. Tne condition increases the temperature in the downcomer region resulting in less subcooling, which leads to possible recirculation pump cavitation, decreased plant efficiency, increased core average void content, increated core pressure drop and '

reduced critical power ratio.

( ) If.a transient had occurred causing a decrease in reactor water level, a reactor scram may not have occurred at its Tech Spec required setpoint of 137" fs TAF (60.2" WC). However, other protective functions were aVailable whicn would help mitigate a level decrease. .

A low water level alarm at 147" TAF from a separate sensor uculd have alerted the control room operators to the transient and manual corrective actions would be taken to restore vessel level.

If level were to drop as far as the low-low level setpoint (86" above TAF), a reactor isolation would occur, followed by a scram caused by the Main Steam Isolation Valves being more than 105 closed. In addition, an indicated level of less than 138" above TAF is an entry condition for tne plant's Emergency Operating Procedures (EOPs). The E0Ps direct the Control Room operator to manually scram the reactor if the automatic scram has not occurred.

The safety significance of this event is considered minimal since the actual setpoint of the low level switches did drift but the switches would have tripped at 136.5" TAF, as calculated from the worst casa drift recorded during calibration. The operator wculd have taken required actions based on level alarms and indications, and the low low level switches would have tripped if level dropped too quickly for operator response.

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wr . . m.w nn CORRECTIVE ACTION A plant shutdown was performed in accordance with Tech Specs, and the four suspect Reactor Low Water Level Scram switches were replaced with the Low Low Water Level model switenes. In addition, the tubing configuration was modified during the switch change-out to facilitate calibration and reduce the potential for entrapping air in the switches. IncreasedSurveilIanceFrequencywas continued after startup. During the upcoming refueling outage, the low level switches are scheduled for replacement witn an analog trip system.

FAILURE DATA 50R DP switch model 103ASB212NXJJTTX6 7-100" WC Range 1850 psig e I' i

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!O Appendix C SOR, Inc. Long-Term Test Plan 1 .

I SARGENT 8 LUNDY O

= ,, .

Commonwealth Edison LaSane County Nuc! ear Station RuralRoute *1 Box 220 O Marsemes. Illinois 61341 Te'e;none 815/357-6761 V

June 30, 1986 Mr. R. C. Engel Regional Manager Static-O-Ring, Inc.

11705 Blackbob Road Olathe, Kansas 66061

SUBJECT:

LaSalle County Station, Units 1 and 2 SOR Model 103 Long Term Test Plan

Dear Mr. Engel:

We have reviewed SOR's Long Term Test plan for Model 103 differential pressure (DP) switches dated June 18, 1986, and have the following comments:

1. Other models of Dp switches such as 103AS-B202, 103AS-B203, and 103AS-BB205 should be added to this test. Model 103AS-B202 switches should be set to trip at approximately 23" W.C. decres 'ing, half of the model 103AS-B203 switches should be set to trip at 143.5" W.C.

increasing and the remainder at 117" W.C. increasing, and model 103AS-BB205 switches should be set to trip at 200* W.C. increasing.

2. The static pressure shif t for the zero and span of the Rosemount Dp transmitter should be measured at 1000 psig and documented.

3. The test plan should contain an ecceptance criteria.

4. The switches should not be adjusted during the test after the initial calibration.

5. prior to checking the setpoint of a switch, the differential pressure across it should be reduced to zero, and the first actuation should be documented.

6. The setpoints for the model 103AS-8212 switches should be increased by 4.2" W.C.

7. The calibration procedure should be attached or referenced, and this data should be included with the test results.

We have also marked our comments on the attached copy of the test plan.

please revise this procedure to incorporate our comments and resubmit it for our review and approval. Also send for our review a copy of your step by step calibration procedures at 0 and 1000 psig.

O

%I .

Document 39881 C-1

815-357-6761, If you have any quastions, pleas 3 contact Ed Sackingar at l

a ext. 284. {

Sincerely, j . S. Abel i Station Nuclear Engineering I i

j Manager I t.

'l J JSA/ELS/cch Attachments l.

I cc: G. J. Diederich R. D. Bishop l

i M. G. Santic I E. E. Spitzner D. L. Rahn E. L. Seckinger

)

i H. L. Massin i

lO 3

4 1

}

} .

1 i

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1.

l i ,

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i 1

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O Document 39881 C-2

Ng am m.,

11700 AAcxsos ROM Jl 6

,,,, g 7 0. BOX :H 1I Oun xmsAs 66061 .

01 4 PO MODEL 103 LONG TERM TEST PLAN 0 1 l @5 l

)

To prove long t::rm set , mint stability of Model 103 Delta-P r

Purpose:

switches as supplied to the -nuclear power industry.

C Objective _:

+

d in the This tes+ is designed to prove the stability of the Model 103 as useThe set j LaSalle Station reactor level safety system. The test is comprised g were selected based on their operational carameters.

of three sections. Section One is a six week test in which the static

[

pressure of approximately 1000 (Hi sidePSIG over low will be maintained w side).

The set pressure of approximately 47.6" W.C. point readings wil D (X) Series taken daily and at 2, 4 and 6 week intervals o f

2 wk. (X) Series taken each 2 week Interval 4 wk. (X) Series taken at 4 weeks and 6 weeks 6 wk. (X) Series taken at 6 weeks These two sections will Section Two is a repeat of the Section One test. both 4 g reinforce each other as well as allow a complete report to be w six weeks and twelve weeks.This ongoing testing program will yield long term using twenty switches. The Third Section will be a The twenty data to support those applications in the field.

log. The :

six week cycle with twenty readings (one for each be considered terminated after 18 months of Section Three test will consistent data. The A series switches will be the control switches (

test set-up schematic).

SECTION I W Procedure:

W Delta-P switches. Install polished O 1. Build 20 #103 AS-8212-NX-JJ TTX6 Install standard cross Use shafts only cross shafts per 8601-008 in 16 switches.

g In 4 Switches. (The 4 switches are to be control switches.)

quallfled material and observe all approved nuclear assembly E procedures. .avet/t 5 /ff y 5 /// fW C(Y/vr/

l

2.

After knal calibratl5D (" Ready toschematic. Ship" condition)

Calibrateinstall the switch Rosemount in a test circuit per attached lo side open to transmitter, Model #1151DP4E12, S/N 794127. (dry), dings on attached q vent, against a water manomoter and record rea itsnre >hf f ef w Rowiecut b calibration sheet. f4nare tN > Mic N- im mt With EQ Her e t open, valvo luc V fill f ufthe an/ c f R with system h H de-lonized e tfa l o Sht h and bleed water 9 3.

from system. I're ss u r u tP .s v i tH to tred o st a, a

i l sor a 8601-009 O Model 103 Long Term ,,

tu ; C-3 ,,,,,

l Test Plan

k1lJ %

.. ~ ,.,. ....

m a,

U K.a 3, s uive i CUme. UNSAF 660dH W'Q") 2H. 2L. DH & DL. (6H & 6L valve 1Lopen).

0 4. Close valves 4H, L, Close equalize valve and Qalibrate 6 0 V"5 Pressuriae system,l to 10004psl. '

/

week switches to approx.:

( )O, 6 WK A - SW + 6 /, / '

j'[

~ < " '" " f . ' [

lO 6 W K B - Wr$" + 6 J. . / '

f /' A r d s /

lj 6 W K C 9" + ( 3. i -

o 6 W KD - 59,S" + 3 r . ; '

6 WK E - 60rS" + ,c,..

Jdy:.I :r d b'i < # j (,,,: -

4 'i' NOTE: HoId dif erentiai h...9 47.6" ressure narafor!ca .:ereminimum sr)of one minute beforc final reading. Obtain increasingObtain set point coming up decreasing set from 47.6" W.C. differential . pressure.

point coming down from increasing set point.

Record base line data.

5. Open EQ valve. yerely sy>l i m pitssa/f is u l ti g ry.

A

6. Close 6H, 6L & Open 4H s 4L Valves.3 Close equalize valve and calibrate switches to approx.:

4 WK A - 56:9" + J /. I '

4 WK B - 57r9" + H l' 4 WK C - 58:9" + 4 r. /

4 WKD - 5979" + 6 Y /"

4 W K E - 60r9" + g g, f .

Obtain increasing and decreasing set points as in Step 4 above and I I record base line data.

g(n {, s , , ri a,,~ p s e v.u re , s a t ic s c ;';g_

7. Open EQ valve.; Close 4H s 4L valves and open 2H 6 2L valves.

8. Close equalize valve' and calibrate switches to approx.:

2 W K A - 58 9" + ri. / ' '

2 WK B - 67rs'U'W & J.i 2 WKC - Sers" + 0 i'-

2 W K D - 5979" + s v. i~

2 W K E - 60 9" + 6 f i' Obtain increasing and decreasing set points as in Step 4 above and record base line data.

9. Open EQ valve. On ft 'p hWU R " ' h'fh

10. Close 2H & 2L valves, open DH & DL valves.] Close equalize valve and calibrate switches to approx.:

D A - St-9* + 41. t

D B - E779" + 6e s '- .

DC - 5679" + (3 i-DE - 59 9" + u f -

- D D - 103" + 6 5. r

{ ) .,9 Obtain increasing and decreasing set points as in Step 4 above and I record base line data.

W g , , , . ,.

Model 103 Long Term

'I . 8601-(09 l Ld c-4 W Test Plan ,,,,,, ,

.. JOX $91 1170$ SU.CK808 ROAD F M StaikD% /ControlDevices oww,. XANSAS 66064 k1 I

11. Open EQ valve.

g.

I h 12. Open all valves (6H, 6L, 4H, 4L, 2H, 2L, DH, DL) and adjust pressure valve and maintain approximately 1000 psl. Close equalize q to jo nW differential pressure Q approximately 47.6" W.C.

SG NOTE: ~1 nts completes initial calibration and estab!!shcs basa !!nc data.

13. Daily Calibrations P.cQ.!^} ,s,, d !Is .

13.a. To calibratefdaily switches:

3

/, ,', f, ' 13 . a .1. Close 6H, 6L, 4H, 4L, 2H, 2L valves; cre,' E& W/ 4- e

' 13.a. 7. Adjust and hold differential pressure at 47.6" W.C. for a

,nc g/. minimum of one minute.

' \ 13.a.7v Increase differential pressure and record increasing set !

[.('l N j '

points.

13. a . Jf. Decrease differential pressure and record decreasing set points.

13.a.5.' Open all valves and adjust static pressure to approximately 1000 psi. ,

13.a.6. Close EQ valve and adjust differential pressure to 8 approximately 47.6" W.C. f U.a./. Maintain pressure in 13.a.5 and 13.a.6. above as close T as practical until next calibration period.

l )

14. 2 Week Calibration Check ,

&42$ ,cspf.!H To,calibratsp2 week switches:

14.a. .

uea ,cn cf '

14.a .1. , Callbcate, daily switches as in Step 13 above.

14.a.2FN Assuse-@at valves 6H. 6L, 4H, 4L, DH, and DL,w

. c4eoet.

14.a.3. Open 2MpGbend- EQ valver. Leriff al.es eN *n/ H. are crem ,

" '" 4'? __14.a.4. sAdjust static pressure to approximately 1000 psi, i

J 14.a 5. ' Adjust and hold differential pressure at 47.6" W.C. for a min (mum of one minute.

14.a.6. Increase differential pressure and record increasing set pcInts. - - --

14.a.7. Decrease differential pressure and record decreasing set t points.

,14.a.8. Open all valves and adjust static pressure to approximately 1000 psl.

' 14.a.9. Close EQ va!ve and adjust differential pressure to

- *:.; :'. x ." approximately 47.6" W.C. . .

" ' ' '." 714 .'

$.10. Maintain pressure in 14.a.8 and 14.a.9. above as close N ~ ~~ ~ as practical until next calibration period.

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15. 4 Week Calibration Check t!RB ..,. L[.!!A )

o i

15.a. To3calibrats34 week switches:

. chd ou d O 15.a.1 4 Calibrats, daily switches as in Step 13.

l 15.a.2 3 Calibrats,2 week switches as in Step 14

[ 15.a.3 F'x Asewe-thet valves 6H, 6L, 2H, 2L. DH, and DI, ace o

cheeed. :_- . _ -

15.a.4. Open 4;;, 4L mJ EQ valves. /errfy n ' <' > "N o</ d v" c/Fe 5

C^' " L' sC15.a.5. 2Adjust static pressure to approximately 1000 psi.

Adjust and hold differential pressure at 47.6" W.C. for a Vs / d - I

)15.a.6. minimum of one minute. '4 15.a.7. Increase differtntial pressure and record increasing set Il points. =l 15.a.8. Decrease differential pressure and record decreasing set l )

points.

15.a.9. Open all valves and adjust static pressure to [l 4 g approximately 1000 psi.

15.a.10. Close EQ valve and adjust differential pressure to '

approximately 47.6" W.C. =

15.a.11. Maintain pressure in 15.a.9. and 15.a.10. above as close . J as practical until next calibration period. 6 16, 6 Week Calibration Check cred tie Lib (

{ ) 16.a. TofcalibraGo6 week switches:

check o.n S 16.a.1. , Calibrate, daily switches as in Step 13.

16.a.2. , Calibrate,2 week switches as in Step 14.

16.a.3. , Calibrate,4 week switches as in Step 15.

~

16.a.4.cugg er valves 4H, 4L, 2H, 2L, DH, and DL.ece- s

, 16.a.5. bpe~nh4taand EQ valver.Wr:fy v d.e s- 6 // %/ U ore cr/n c/c.e te (16.a.6. . Adjus't' static pressure to approximately 1000 psl.

v>Id )16.a.7. ' Adjust and hold differential pressure at 47.6" W.C. for a ,

minimum of one minute.

16.a.8. Increase differential pressure and record increasing set a points.

16.a.9. . Decrease differential pressure and record decreasing set points.

16.a.10. Open all valves and adjust static pressure to approximately 1000 psi.

16.a.11. Close EQ valve and adjust differential pressure to t approximately 47.6" W.C.

$ 16.a.12. Maintain pressure in 16.a.10. and 16.a.11. above as l

, f.i ,,..

close as practical until next calibration period.

i i

i

~ 17. This completes SECTION 1 Testing. I

) oo n t a dy s t t/e .setpw is a tle swide s yl.

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i Procedure:

a 5O Section 2 testing is identical to Section 1 Testing (beginning on Week 7).

a to 5G o

SECTION 3 . . .

Procedure:

1. Section 3 testing is to be done at Week 12.

2. Additional testing is to be done at 6 week intervei%

3. During Section 3 testing , all twenty switches are to be checked concurrently.

9 '

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Model 103 Long Term LET 4 8601-009 I g .m ppy,(yy

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DH D D D D D DAILY ,A B C _D E DL EQ

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SWITCHES- SWITCHES = .= ,

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ROSEMOUNT CALIBRATION SHEET l IO i

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i

8. eO .

Date BEFORE TEST Manometer Rosemount (In. W.C.) (In. W.C. )

O e

10 20 l 30 40 50 60 7c

( ) -

s ::

10 .

! tl i,' A Date _ '[

AFTER TEST ,

Manom'eter Rosemount.

(In, W.C.) (In. W.C. )

0 10 20 30 40 50 60

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( )H ss c I f' o ________-

(A -

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O Appendix D SOR Differential Pressure Switch Setpoint Characterization Test Data Graphs SARGENTS LUNDY O

=_

l .

TABLE OF CONTENTS FOR APPENDIX D GRAPHS PAGE O I. REACTOR VESSEL LEVEL 3 ALARM j A. Switch 2B21-N024A l

1. Full OP dated 6/19/86

a. Static pressure effect D-1

b. Hysteresis D-2

2. Mini OP dated 6/28/86

a. Static pressure effect D-3

3. Mini OP (new setpoint) dated 7/8/86

a. Static pressure effect D-4 B. Switch 2B21-N024B (existing)

1. Full OP dated 6/19/86

a. Static pressure effect D-5

b. Hysteresis D-6

2. Slow approach to setpoint dated 6/21/86

a. Static pressure effect D-7

b. Hysteresis D-8

3. 4-hr. static pressure test dated 6/21/86 D-9

4. Full OP dated 6/23/86

a. Static pressure effect D-10

b. Hysteresis D-ll

5. 24-Hr. static pressure test dated 6/23/86 D-12 C. Switch 2B21-N024B (replacement)

1. Mini OP (new setpoint) dated 7/8/86 O D.

a. Static pressure effect Switch 2B21-N024C

1. Full OP dated 7/6/86 D-13

a. Static pressure effect D-14

b. Hysteresis D-15 E. Switch 2B21-N024D

1. Full OP dated 6/29/86

a. Static pressure effect D-16

b. Hysteresis D-17 F. Switch 2B21-NO38A

1. Full OP dated 6/17/86

a. Static pressure effect D-18 l

b. Hysteresis D-19 l G. Switch LS-2B21-NO38B (existing) l

1. Full OP dated 6/17/86 !

a. Static pressure effect D-20 l

b. Hysteresis D-21 {

H. Switch 2B21-NO38B (new)

l. Mini OP (new setpoint) dated 7/09/86

a. Static pressure effect D-22 I. Spare (B203) Switch 86-1-3269

1. Full OP dated 6/24/86

a. Static pressure effect D-23 J. Spare (B203) Switch 86-1-3270

1. Full OP dated 6/24/86

a. Static pressure effect D-24 i

DOCUMENT ID 40361/

TABLE OF CONTENTS FOR APPENDIX D GRAPHS (Cont) l II. LEVEL 8 RCIC TURBINE TRIP l

A. Switch 2B21-N101B

l. Mini OP dated 7/3/86 l

a. Static pressure effect D-25 III. REACTOR WATER LEVEL 2 HPCS INITIATION A. Switch 2B21-NO31A

1. Full OP dated 6/13/86

a. Static pressure effect D-26

b. Hysteresis D-27 B. Switch 2B21-N031B

1. Full OP dated 6/16/86

a. Static pressure effect D-28

b. Hysteresis D-29 C. Switch 2B21-NO31C

1. Full OP dated 6/13/86

a. Static pressure effect D-30

b. Hysteresis D-31 D. Switch 2B21-N031D

1. Full OP dated 6/14/86

a. Static pressure effect D-32

b. Hysteresis D-33

'g E. Switch 2B21-NO37AB

1. Full OP dated 6/15/86

a. Static pressure effect D-34

b. Hysteresis D-35 F. Switch 2B21-NO37BB

1. Full OP dated 6/16/86

a. Static pressure effect D-36

b. Hysteresis D-37

2. Mini OP dated 7/1/86

a. Static pressure effect D-38 .

G. Switch 2B21-NO37CB

1. Full OP dated 6/15/86

a. Static pressure effect D-39

b. Hysteresis D-40 H. Switch 2B21-NO37DB

1. Mini OP dated 7/1/86

a. Static pressure effect D-41 IV. RHR HIGH SUCTION FLOW ISOLATION (Shutdown Cooling)

A. Switch 2E31-N012AA

1. Mini OP dated 7/3/86

a. Static pressure effect D-42 B. Switch 2E31-N012BA

1. Mini OP dated 7/3/86

a. Static pressure effect D-43 l

i 11 l l

DOCUMENT ID 40361/

TABLE OF CONTENTS FOR APPENDIX D GRAPHS (Cont)

PAGE

() C. Switch 2E31-N012AB

1. Mini OP dated 7/3/86 D-44 i

a. Static pressure effect D. Switch 2E31-N012BB

1. Mini OP dated 7/3/86

a. Static pressure effect D-45 V. h(R/RCIC HIGH STEAM FLOW ISOLATION A. Switch 2E31-N007AA

1. Mini OP dated 7/1/86

a. Static pressure effect D-46 B. Switch 2E31-N007AB

1. Mini OP dated 7/1/86

a. Static pressure effect D-47 C. Switch 2E31-N007BA

1. Mini OP dated 7/2/86

a. Static pressure effect D-48 D. Switch 2E31-N007BB

1. Mini OP dated 7/2/86

a. Static pressure effect D-49 VI. RCIC HIGH STEAM FLOW ISOLATION A. Switch 2E31-N013AA

1. Mini OP dated 7/1/86 ON a. Static pressure effect D-50 B. Switch 2E31-N013BA

1. Mini OP dated 7/2/86

a. Static pressure effect D-51 C. Switch 2E31-N013AB

1. Mini OP dated 7/1/86

a. Static pressure effect D-52 D. Switch 2E31-N013BB

1. Mini OP dated 7/2/86

a. Static pressure effect D-53 VII. REACTOR WATER LEVEL LOW LOW MSIV ISOLATION A. Switch 2B21-N026AB

1. Full OP dated 6/18/86

a. Static pressure effect D-54

b. Hysteresis D-55 B. Switch 2B21-N026BB

1. Full OP dated 6/18/86

a. Static pressure effect D-56

b. Hysteresis D-57 C. Switch 2B21-N026CB

1. Full OP dated 6/18/86

a. Static pressure effect D-58 g-'S b. Hysteresis D-59

( ) 2. Mini OP dated 7/4/86

a. Static pressure effect D-60 111 DOCUMENT ID 40361/

TABLE OF CONTENTS FOR APPENDIX D GRAPHS (Cont)

PAGE D. Switch 2B21-N026DB

1. On NRC Hold NA VIII. LOW LEVEL 1 ADS, LPCS, RHR INITIATION A. Switch 2B21-NO37AA

1. Full OP dated 6/14/86

a. Static pressure effect D-61

b. Hysteresis D-62 B. Switch 2B21-NO37BA

1. Full OP dated 6/16/86

a. Static pressure effect D-63

b. Hysteresis D-64

2. Mini OP dated 7/2/86

a. Static pressure effect D-65 C. Switch 2B21-NO37CA

1. Full OP dated 6/15/86

a. Static pressure effect D-66

b. Hysteresis D-67 D. Switch 2B21-N037DA

1. On NRC Hold NA IX. RHR PUMP LOW FLOW MIN. FLOW VALVE OPEN A. Switch 2E12-N010AA

1. (No Graph) NA C) B. Switch 2E12-N010BA

1. (No Graph) NA C. Switch 2E12-N010AB

1. (No Graph) NA D. Switch 2E12-N010BB

1. (No Graph) NA E. Switch 2E12-N010CA

1. (No Graph) NA F. Switch 2E12-N010CB

1. (No Graph) NA X. LPCS PUMP LOW FLOW MIN. FLOW VALVE OPEN A. Switch 2E21-N004

1. (No Graph) NA XI. HPCS PUMP LOW FLOW MIN. FLOW VALVE OPEN A. Switch 2E22-N006

1. Full OP dated 6/16/86

a. Static pressure effect D-58

b. Hysteresis D-69 O

iv l

DOCUMENT ID 40361/

l 1

l TABLE OF CONTENTS FOR APPENDIX D GRAPHS (Cont)

PAGE C'\

U XII. MAIN STEAM LINE HIGH FLOW ISOLATION A. Switch 2E31-N008A

1. Full OP dated 6/20/86

a. Static pressure effect D-70

b. Hysteresis D-71 B. Switch 2E31-N008B

1. Full OP dated 6/22/86

a. Static pressure effect D-72

b. Hysteresis D-73 C. Switch 2E31-N008C

1. Full OP dated 6/23/86

a. Static pressure effect D-74

b. Hysteresis D-75 D. Switch 2E31-N008D

1. Full OP dated 6/27/86

a. Static pressure effect D-76

b. Hysteresis D-77 4

E. Switch 2E31-N009A

1. Full OP dated 6/21/86

a. Static pressure effect D-78

b. Hysteresis D-79 F. Switch 2E31-N009B

1. Full OP dated 6/23/86

a. Static pressure effect D-80 f- D-81 t b. Hysteresis G. Switch 2E31-N009C

1. Full OP dated 6/24/86

a. Static pressure effect D-82

b. Hysteresis D-83 H. Switch 2E31-N009D

1. Mini OP dated 6/28/86

a. Static pressure effect D-84 I. Switch 2E31-N010A

1. Full OP dated 6/22/86

a. Static pressure effect D-85

b. Hysteresis D-86 J. Switch 2E31-N010B

1. Full OP dated 6/23/86

a. Static pressure effect D-87

b. Hysteresis D-88 K. Switch 2E31-N010C

1. Full OP dated 6/28/86

a. Static pressure effect D-89

b. Hysteresis D-90 i

DOCUMENT ID 40361/

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

TABLE OF CONTENTS FOR APPENDIX D GRAPHS (Cont)

PAGE O ,

L. Switch 2831-N010D

1. Mini OP dated 6/28/86

a. Static pressure effect D-91 M. Switch 2E31-N0llA Mini OP dated 7/1/86

1.

1 a. Static pressure effect D-92 l N. Switch 2E31-N0llB

1. Mini OP dated 7/1/86

a. Static pressure effect D-93 O. Switch 2E31-N011C

1. Mini OP dated 7/1/86

a. Static pressure effect D-94

p. Switch 2E31-N0llD

1. On NRC Hold NA 1

, O l

}

i l

1

O vi

'I DOCUMENT ID 40361/

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. _I Existing Allowable Tolerance
( _), 4. 5 0 ;i . i.ower timi t (1sg.a3 7 i 1655 o _ _ g i7@ 4...........-}............' .......................}....-...... D e s i r e d Se t P o i n t ( 17 9. 0 )
~
C [ ' ' ' A O 175a P ' CL. -
-H 160[J : existing 4tico,3i, 7,i,7,nc, Ur p e r L imi t (100. 91 f 4. T. S. P.
g t o , 18 5 _: 190 i i i I I i i i i ! 1 2 3 4 5 6 7 8 9 10 Actuation H c .i. 1 te ,.;,i H c,.i. : t i... ,.; ,q + c,.. . : t, ,,,,, c,.i. , u ,,, ,.,,,
O O O S.Il0-V,- $1I18 J1::OrelLlal3reSSure 6 Swi:ca Opera)iLi:y "es: Da:a 150 2331-N133A 7R2/83 / / q Test #1 (Static Pressure Effect) 1 155' 2 Existing Allowable Tolerance U lb@ H Lower Limit (161. 01 3 l 165] o v
]
4 -W 17@ Q%............. ....................................... D e s i y e d Se t P o i n t C 17 4. 0 )
---===L-.--.-n-..1-_-.. - 4 4 - i i#g " ~1 O
Q_ b, - u 160 -! Existing Allewable Tolerance g Upper Limit (179.01 N. T. S. P. 185 4 d 190 ' ' 1 2 3 4 5 6 7 8 9 10 ACidaiiOrl r o. 1 m ,. , ,, g c ,. . . m , m ,. , ,, .c...,o..,, . c ,... . u m ,.,, q 4
O O O o Alc-0
,SlIlg 31EerelElal 3..reSSllre Swi ca 0 Pera')ili;v. Tes; Da:a 150 ,
2E3A13A3 7 ':183
} Test #1 (Static Pressure Effect) 155d ^ . i 4 Existing Allowable Tolerance g 160H '
tower Linit cisi. o _'_-s f
-l 165-~ -
a ~1 b y 1 7 0j -k---------------------------------------------------------e D e s i r e d Se t P o i n t ( 17 8. 9 ) c-- t
'~ ;
2 C 3
- 175--
Q_, - u 180 Existing Allewebte Tolerance g _ Upper Ltait (179.9) N. T. S. P. ar) 1 8 5 a: - 1 i ! i i i i i i igg 1 2 3 4 5 b , 8 4 10 ACIUaiiOTI
p c,.i.tc ...., r c,...

u... ,.,,q + c...:<... , r c,.... m... ,. ,i i.
O O O S,la;10-V-SlIlg .J1: OTOIl lal yTOSSllre . Sn. :ca u,pera)ih.;y ,,eS; .Ja:a 2331-E1333 7 02/83 150-Test #1 (Static Pressure Effect) 155-~
^ :
Existing AllowaDie Tolerance U 16@- Lowe r Lim i t (161. 0) y _
~
165- . e x v
$: y 170{r-w=; ." ;Z~.!---- C-------- '----------- *-----------g D e s i r e d Se t P o i n t ( 17 9. 9 )
c :
'- 175~
a- : y 180 - Existing Allowable Tolerance Upper Litrit (179. 9) N. T. 9. P. g Cn 1 8 5 _: ! 1a 1 I I I I I I i ! ! -g1 2 3 4 5 6 7 8 9 10 Actuation H cy.i. t a ,. ,, p . cy. . : u... ,. il_.>.c,.i.1 a ,.ig 9 c,... u . ,.i,i
O O O h,;a';iC-0 31I18 J1 OreIl;lal 3..reSSllr0 e r1 Sw1:ca 0-) era,)n.. .:v .eS; Ja;a 138 , 232 -E26A3 3/18/83 Test #1 (Static Pressure Effect)
.m 140-CJ - Existing silo'nable Tolerance . ' Lower Limit (141.W:
7 id2-o "
1 a ........ .................................... .............e D e s r e d Se t P o e n t C 14 3. 4 ) 2' iddd% .-; m o o :y__ ~~ ._ , __ Existing Alloisable solerance
,3 ; Opper Lut s t (145. 61 Pl. T. S. P. +-
1, - Cn 143J !
! I I l l 1 l } I T
1 4 5 6 7 8 9 10 1 1-A C t. U a t i O T1
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h h c c t t n0 i i w w s P s o e . e en m3 s 3 cS sP 4 a n I i" rT iA c c 4 e I r" r0 i 1 I . e0 o ( oN e x2 T T v0 1 t ) I e e e1 i . n eb i . m m 1 i b5 ao 4o o I r d1o( 4 P a4 w1 o( I &f r &f i t I e 2g Mt'm s 1t Ai m l 1 g n si n i d 9i si e L e nL i I et et r r tr r tr l r l ca u s
)
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. 140-U : : 5 =
5 J 1 1 ~ Existing Aliowable Tolerance
j d Lower Limit (141.31 1 dcq
, ~,.......a...........i- _-j.........[...........DesiredSetPoint (143.3) m , ,
164 d Fwww. - _-___ 7
f. w C /
o 1 Existing Allowable Tolerance
! ; Upper Lmit (145.6) N. T. S. P.
1454 I
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Test #1 (Static Pressure Effect) m 140-U
" Existing Allowable Tolerance
__= { ' Lower Litu t (141. 3)
" 142-o a 1 , E A g p......... ~
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" 144 - ~Y T17C~
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; Upper t.mu t f145. 6) N. T 5. P.
1 f 14bHL __ a b ~ CO 148-i i i i e i i i 2 3 J 5 9 ; 1 6 7 10 1 1-A C t u a t i Oil i_e_ev.t. ce ,.i,i j - - cy.t. a cteen ,.;,1 l _+_ cv.t. a te p.iya j - _ cu t in citee ..i,, j
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0. litig Ji::erert;ial 3. resstire SWlle3 V, era)11J neS;3318 O'30 U'00D3 3 0 /04 4JG. --Ju kUbJ 0 .U/ 00 gg[ Test *2 (Hysteresis. 10b0 psig)
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i a. I e .t , .sc ___' 4....................................................................---> E::istin? Allewabie To1e mee Lower L w t (131.1:
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.. e Q7Q < n g/ \J 4} N ( ; .Q f6 196 ,
404 -h'u'dlk'i U// I-00 j Test *1 (Static Pressure Effect) 197 i -
, Ey e sting At towable Tolarance O
J. g .v01f ' Lower Lim i t (197. 301 4 J _a ,- H 2 idsj J _, [- @ @ _4. .. .... .... .. .. .... .... ...... .... .. ... ... .... .. .. .. .... .e D e ; i r a d Se + P o i n t f293.991 o -s
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204 1
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a-hIn37nA v : o!/n*/di^ o 1 Test #1 (Static Pressure Effect) 198 3J
^ J Existie7 Atlewsbie Toterwee Leve- Lim,' ft97,99) v 199Ja . ; e e _1..... ..... . . ... .. .. .. .... ...... . . ..... ....... ... . ... . .. .. . 3 e , , , , e 3 e t % , ,1 ou, u, m
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_ Test *1 (Static Pressure Effect) m - e (_; ~ 195-
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;
Lower Limi- fi97. 91 w, -
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Swl:ca Olerari v, ,,es; Ja:a . 195 , 232 -N037CA 6/15/83 i Test *1 (Static Pressure Effect)
.s 1974y H Existing Allowable Toleranca g ,gg . Lower Limi t fi97.601 a . 1 2 199 1 a ?_. 2 0 0d---------------------*h W / - M-----------. D e s i r e d ec t m e n t usa.aai 5' J / . $ u -- ~hg >-
999
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