ML20210U101

Forwards LER 50-255/83-74 & Event Rept E-PAL-83-204 Re Failure of Valves to Meet as-found Acceptance Criteria in Tech Spec Test RM-29

ML20210U101
Person / Time
Site:	Palisades
Issue date:	08/29/1984
From:	Norelius C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:	Spessard R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20210T938	List: ML20210T935 ML20210T945 ML20210T968 ML20210T983 ML20210U001 ML20210U023 ML20210U054 ML20210U101 ML20210U153
References
FOIA-86-266 NUDOCS 8606020172
Download: ML20210U101 (11)

See also: IR 05000255/1983074

Text

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. , August 29, 1984 MEMORANDUM FOR: R. L. Spessard, Director, Division of Reactor Safety , FROM: C. E. Norelius, Director, Division of Reactor Projects SUBJECT: REQUEST FOR ASSISTANCE (Evaluation of LER 50-255/83-74 for Palisades) Attached is a copy of a written report of an event at the Palisades , unit dated November 9, 1983. As discussed between W. G. Guldemond and G. C. Wright of our respective staffs, we understand that you plan to review the attached LER (50-255/83-74), EventReport(E-PAL-83-204), and internal CPC0 memo and to provide your position as to the safety significance of the event, d "Griginal signed by .R. F. Warnick C. E. Norelius, Director Division of Reactor Projects Attachment: As Stated cc w/o attachment: G. C. Wright, DRP W. D. Shafer, DRP B. L. Jorgensen, SRI . 8606020172 860516 .* PDR FOIA , MURPHY 86-266 PDR i 1 _kh

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. M -N . 6' *-u i .. - 7.,0,. ,4. p. .t . .. m. _ . . . 1 . EVENT REPOR %6/g ga..n,o &.b ,,wn ,n s l g- A - .a.n.c; ... y... i t ~ . - ou y RGe10 G~/W. tr/gle, d .. m - ~. ,_ , n"" ' .. l IK4TlflCATiry: A m IUCrtPTim i l FARI I i y Iata: _Valies_fgile_d_to_ Meet the ' A_slp_und ' Actepiante_fr_ileria FouncLin Tecanica1 ___ Pnecirlcatinnn Test _RW P9 .B_ jeu.,i. sit.nrei- 04110 - levie.c.: . (tassnni 13107 . _ _ _ _ _ _ - d usce er.0 0, uc.en.ct ce c>ea.0 - rw or neRV-0701 - -072L_ On 10-3-83. SE&Ls_ began testina Palisades r.ain steam relief valres_at__the_BC_Cobb_. Plant . Iterveen_ott . L anroet. IT. the 'as f_o3uld test _n vere en pl eted_ on_RLD701_thronch RV-D721. RV-0715..vas_found_vithin the +nct 4 The remn i ni n e, 23_rel i a f valve n vercJnnna vith l i f t pn i nt e criterjn- that e;enaded the tb critarin. _In n11 enene the,lV l i fted in_evenec nf the +15 evitorise. Th o ' p *ift pointn vere aveceded from n lnu nf 1_35 tn . n mirm nf 11g_9 0 Theep vniven ve"a re-a g21 anri g tha 1==t va rn al i n g nut:y n and t este d_by_SPATR Tn all races, t M y

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p e Osan acrac.: _ \\M WN W *2U " - m Each vn1va hae.heen Mi nn ena-bled and rebuilt by the crashy__ Valve Cn- service rep- New internni pnrts_bava_baan reninead where naadad- All r*liaf valven hava haa" ratested nna maet the_acceptnnch eviteria._enll ed fnr in R"-29 1.1 strut.us: Tg Tent p wpg. nort.g Tent p-nc _ F,) "t"n0 s' EEr_i_qhfg "";11-10-83 V-M- ' 1 hint _Eroc MAA-M-1n_ -e M1 ' 0"'""" .TT'I/& PA '"""; r TE , 3 ,:,ce.,:e..e.n. ni U .3 A s une.....,=_ f &.te. k p,.p h uu.,,n: Yl4!l3 M e. ,ee.a n o v0 " n gjam """ " J Q - __ , ""' l - ', g , ,,g . , v ! PEVIEV A';D NOTIFICATIG's -uoep. = A_) att0stant r0 .ec;

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- FORWARD ALL CORRECTIVE ACTION 00CL*ENTS THR0tKN YOUR CORPICilVE ACTION ~ ,, - ,

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fce9 OA-t3 rcea ca-20 (moit SECT 80m 10 WalCII &Dcefl04tL teFoestattosi APPL egs) PaCf ~ CF ~ - *f V -Ih & -JD - . Part_._1C,_Descr_intjon .o_f_ Occurrence or Condi_ tion: (cont.) t 2 __ fnund tn be leakine,_ bad.ly_ani_re. quired reset 11 NIL.to__rael_the_Aec2Rtance criteria. That_adlustr.ent_r.av be_ the reason for the high lift coints en,ma auring tha lor 3 ta=te. - Par _t_3B_IVALUAT10N__AND_ DISP.0SLTION__ ROOT CAUSE fennt.) __ After reviewing the test data. I disagree with the Crosby representative. The. valve dischnvra majnetrant di d affect. li ft preennren. T believe that the took pince- - - - fnlln'Iirgq_.s e e" 4 * i n _ __ . ' l. The valve discharge heights were adjusted in 1961. . 2. "The valves vere then tested'and consistently found to lir_t_at_a3ver

rressure_than reiuired. - ~ ' l ' 3. The valyes were then read.1usted to a higher lift pressure. h. They were ratested_vith the ad iiie,t.{di sc h n rge ' heights and tested Rood. . 9. The vni va aiceherra haichte vere renainnrea tn nricinnl d e m i en and the vn1 van reinslalled. ' ' '

.- ~ J 6. In 1983 the valves were retested without adjustment using a test rig with - a large accumulator. The valves consistently lifted at a Ic - m pressure than reenived. Wdd Fff

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for__the dischar.ge height._adlysfr.ents . When tested in 1983 the valves Dai-form' d g3 thay vould in s ervi c e . e A1.l~the Main Steam RV's have been rebuilt and tested, without discharge height _ adjustment, using a test rig that simulates actual plant conditions. , f - p L-WZ- _ - ....... _ ... ......-...._. ..,....._, . _m ./ Z , _7_-b'_:S - - . . _ _.....s.., .._....s .q , _. ,_ , . _ _ 1 . . - ..m

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'g I ,. .e.- l' E -PAL.i em- 8 3 --20 L '- .e % De_q main steam relief valves (RV-0701 thru RV-072h) are canable of cerforming their s_ign_f_unct ion . found' set ooints.The results from 1981 R%_2_9_t_esting indicated extremely _lov 'as from predescribed factory setti_ngs.These values were obtained after the nozzle ring was_ajil _. The nozzle ring _a_djustment was necessary_t_o_de- _c te a ss_ blowdown d u e_t o_ tnt __.syS_t e_ q_l imit at i ons ,_i_e, _t.ht_tts1_sy_sita.f iLD o desired steam generation capacity. t _ cated that set ooint was not affe'eted by nozzlT ilng_adj~ustment.The valve manufactur - -~The valves were inspected, cleaned and retested. The spring tension was adjusted { increased) to_ achieve or_ooer lift. Reps 1Jtly.e__1.ifts were cerformed to demonstrate rel.iability. , Upon cocoletion the nozzle ring was returned to the factory setting and lock vired. -- . _Ibe 1083JX-29 tentlnc indicateLextre:aly_bigh 'as found' set coints. Th ese_._y_a_l_uts _Sete_ o_b_tain e.d_.xit baut_prio r_ adiu st r.ent s . The_1981 te.st system steaq_cepacity was - ' imprnY.eChetween_1981 and_19&.'i. Therefore. the_ nozzle _rjnr adlustment was __p_t_nec- -- The -valves vere insoected. cleaned. repaired and/or relanped under the direct _ _gs sary. n supervision of the manufacturer's field service representative. tested with the spring tension adjustid l ecrease~d) to achieve procer lift.The valves were re-- - pipe _.yas_ removed _and at 40jlof_ set _. point. prissure the_.ya Repetitive ~ for Isak_tJghtness. - ' In_recent_ telephone cony _ersations vith D. A. Desnover (CPCo - TraH __Tuttle (Crosby _ Company Stre_cil_and_D.. -- ' _ _. set point relationshio was clarified.- engineerind the_Cr_qsby_ position on the _nnule ring and _ . _ No_xg_al_ly . the nozz_le ring is not adlusted. . I f__ ; the-- nozzle rinc is adjusted it is usually only .1_a_ ins _that nqr_nal, minor __ adjustments vill not affect set point _.one to three- . notches..'!_. a f f 192erincl.he_ngizle_ ring .of s.safetv =alve c ?,ld i ureta ver. TTeh el.an i e wld They added that cause a sli was in 1M1[cht__incre m ir. ct.r i ..: :.rw.aute . -Cpr_.v.;r+1 ;.,_iW_r.j_s-iire -er.: - 2 _bs it raising the nozzle ring could cause a slight decrease in ooppine pres- During the 1981 testing the nozzle rings were adjusted as mucE Ils 12 "dotches. - sure. - , In addition, the instructions bulletin for operation and maintenance of Crosby safkly - valve . _ Vendor . File.EI.-F-.D , _ state s_: "If the valve pop _s too lov. the seats may have becgme damaced. Low popping . . _ ._ pr. essure _._is_ seldom caDERd_by_ Spring _ set.. althouzh this is considered a _ cog:pon cause. " _.The_above information ind_icates_that set points can be influenced by seat condition ~ __and_no J_le_f_ing Ad,1ustments,although_the exact relationship can not be determined. _ Suffice to state that the 1981 R'4-29 'as found' test results were in error, infl'u~- enced by leaking valves and nozzle ring adjustments. The corrective action (soring tensioning)_taken durin5 the 1981 R:1-29 test caused the deviations observed / recorded ~ _during the 1983 testing. As stated above. the main steam relier valves (RV-0701 thru ltV 072h) are capable of . __ performing _JE-29_ test _._has_the_. adjustment _bplt ltontrg1S .. of_the ;1903 _Q1;;ple_ tion - _.in_v_ithin._.l 25_ flat.s_at_the_'as_found '._positipa_qr._the._19&LBM-29..t.es_t_.__ ln additio _they__hayt_ individually _bten_. inspected < for_ lea}s__tigh _. retur_ned _ ._g_uppott.ive evidence can be shown (see _ Attachment 1)tniss.. Non-conglysjve but __numetical average of the observed 'as found' lift _ point during both the 1901 an_dThe bo . __19633M-29_ tnt.s. AllbDt_pne_YA.lve_.f_ alls _yithin_th_e recommeAd_ed set eqint__t_ ole _taDee _ hand _ - %e aggreEate of the above informafi_on is the basis for the concluYionT'sef,~for'th. _ _ - . - . _ _ _ _ - g 434g__ , / - - _ l - - - - , - - - _ -+ . - - - - - , - . - - - . - - - - - - ~g . -- e --, . - - , . , .--,--._w-e--.- _

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' . " " .- e ,' 3 - . . , , ' . . . '- To P-CARB From MJBaker,P24-404f*(J]33 - CONSUMERS POWER Date June 8, 1984 QOMPANY Subject REACTOR ENGINEERING RESPONSE TO E-PAL-83-204C, Internal STEAM GENERATOR SAFETY VALVES FAIL TO MEET ACCEPTANCE CRITERIA Correspondence MJB 84-001 Ref 1) XN-NT-77-18, Plant Transient Analysis of the Palisades Reactor , for Operation at 2530 Mwt, July 1977, and - 2) Phone conversation, Mel Woolpert, Combustion Engineering, 5/31/84. Between October 4 and 14 of 1983,' steam generator safety relief valves RV-0701 through RV-0724 were tested for proper lif t pressures. Only 1 of the 24 valves was found to lift with~in the ASME code acceptance band of 11%. Event Report E-PAL-83-204, part c raises the question of the impact of the "as found" settings on the existing Palisades safety analysis. The purpose of this analysis is to determine what effect, if any, is created by this discre- pancy. It is the opinion of RED that the Palisades plant was not in an unsafe condition as a result of the a' found" safety valve settings. However, the s ~ plant was in an unanalyzed and potentially unsafe conditior.. basis transients (Ref 1) . challenge the secondary side safety relief valves.Four licensing The increased lift pressure would alter the results of the above mentioned E' analysis. However, for this case, it is our belief that the "as found" sa fety valve setpoints would still yield acceptable results for the transients in question. Regardless, it should be stressed that:.1) our findings are based on engineerings approximations, and 2) increased drift in these setpoints could create an unsafe condition. to insure safe operation of the plant.We recommend that this problem be corrected If it remains difficult to hold these values within the 11% acceptance band, a widening of the band is possible. (Ref 2) The four transients which challenge the secondary safety valves are as follows: . A. Rod Withdrawal from 102% Power, B. Rod Withdrawal from 52% Power, C. Single Control Rod Withdrawal, and D. Loss of Load. Transients A, B and C reach minimum departure from nucleate * boiling ratio (MDNBR) at the time of reactor trip. The secondary safety's don't open until a considerable time af ter trip. At that time, DNBR has increased and is no longer an important factor. Primary system pressure remains low during these transients, never being greater than 2210 psia. Therefore, the safety valves have little or no affect on safe operation in these transients. loss of load transient' challenges peak primary system pressure (52750 psia) However,-the primary seconda ry AP (51530 psid), and MDNBR (21.30). , In this transient, the secondary safetys are need to relieve pressure in the carly stages . ,and . --.... _

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. a 2 .- , . therefore are an important element in mitigating the consequences of this event. Three loss of load cases were analyzed in Ref 1. . . is the worst with respect to peak primary pressure.(See attachment 1) Case 1 effect of delay safety valve opening on peak primary pressureAttachment 2 sho

safety valves were assumed not , to open until the highest The secondary . for group I was reached, clearly a conservative assumption"as found" setting pressure reached 2450 psia, much less than the 2750 psia technicalPeak primary . tion limit., Attachment 3 shows the estimated AP as a result of a secCas secondary AP specifica- . setpoint for group 1 of 1037 psia, as in Case 1. ondary safety valve psid, well below the limit of 1530 psid. The approximated AP = 1424 . ' technical speci_fication. Limit on DNBR of 1 3 Case 3 challenges the Palisades Reactor Engineering feels that delayed safety valve opIn this case l^DNBR'= 17 . . , _ ,, effect on actual fuel performance. Other Torms 'of see'o denin,g wo_uld.have little.. are. conservatively ' ass'uded inop"er%fE 'fo'r' 'thiscas n ary pressure . relief atmospheric dump valvesand' 'c'onde'n's'er' bypass would be' a.In reality, -the - e. . r- pressure. of the W-3 DNB correlation which has a license DNBR li itAn ,- , is the use provides additional operational margins. accurate XNB DNBR c m of 1.3. The more o 1.17 which sufficient margin of safety, to offset the change inWe feel these conserva,tisms yie . . safety valve setpoints. Therefore, Reactor engineering concludes that the P li ... an unsafe condition due to the improperly set valve sades Plant was not in a - the existing safety analysis.should be maintained at their required s However, the valves s. within the bounds of < ~ . - . I

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3-fi company . .~, ..u~ Geaeres omces: 212 west uscas en Avenue. Jochton. Mech gen 49201 * Aves Coce 017788 0330 s December 9, 1983 ' , James G Kepplet, Administrator Region III - US Nuclear . Regulatory Coc=ission 799 Roosevelt Road Glen Ellyn IL 60137 . DOCKET 50-255 - LICENSE DPR-20 - PALISADES PLANT - LICENSEE EVENT REPORT 83-74 (VALVES FAILED TO MEET "AS FOUND" ACCEPTANCE CRITERIA) , ,. . Attached please find Licensee Event Report 83-74 (Valves Failed To Meet "As Found!' Acceptance Criteria) which is reportable to the NRC per Technical - Specification 6.9.2.b(1). Brian D Johnson (Signed) , . Brian D Johnson Staff Licensing Engineer CC Director, Office of Nuclear Reactor Regulation Director, Office of Inspection and Enforcement NRC Resident Inspector - Palisades ] j Attachments .' , I evwr OCl283-0004A-NLO2 , < _

f M . ~ . , PALISADES PLANT - DOCKET 50-255 . - . .. . . .

, u.s. Nuctas.= ntoutATony couuiss oN LICENSEE EVENT REPORT CONTROL SLocat: l l l l I l .h l (PLE Ast PalNT CR TYPE ALL RIOuta:D INFORblAT10N1 i R, l M lT lPlAlLl1l@n 0l0 l-l 0l 0l 0 l 0] Ol 4 Ol Ol@ h l1 l1 l 1l 1l@l l l . c., g . . oc. ...cooi .. uci~u o-um n 2. uci~is T.,. . con'T l, o l ' .1 % % LL_1I)l015101010 I 21 si G. .l.i 11101 cl 813 Gli l 21 0] 91813 J.@ , . ., ooc. n ~o,s... . ....io.n 3. n m. on, .n .. EVENT DESCRIPT80N AND PRO.a.LE CONSEQUENCES h

o ! 21 I While shutdown for refueling, e routine refuq1inc duration surveillance tesy

[o [3 y I revealed that fourteen of twenty-four cain stee.= relief valves lifted at lo la j Ipressures in excess of the urner lirit sreci fied in TS ~4 1.7. . , "w . v n '1 ' 9.- ! c.3 Io i s i I are believed to have been able to provide their intended safety function I[ e 152cvever. evaluation is incorplete at this tire. Notification vill be r o- I o s

o g ,4 j vided if final analysis is to the contrary. Reportable per TS 6.9.2.b(1).

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sa 90 v. l - um sig n L.IJO 'v' o f o! o I o f LIJ@ 1xJO. LA@ f c 17 11 IOI@ 22 sa 2s 2 .o ai u . . ., CAUSE C($0RIPTION AND CORRECrivE ACTIONS h , . , ICeuse is believed to have resulted frc ad_iustrents rede to each valve's I i o bl m i evdown ring which affected the lift setting. These adjusteents were cade g subsequent to the final lift setting adjusteents cade during the 1981 , l Refueline Outere. The test rrocedure vill be reviaad to rrevent bl evdevn I i 2 i adjustments prior to "as found" testing, and subsequent to "as left" testing 4 , , . . AN s rouwt m oT=gn gTatus D o a oescovtav otScaerTeoas La)@ In i n I nI@l un i L.P.J@l > $ e., e m ~. s. ,,mt i 7 . 12 13 as e as 0 afLEa3fD o#mgLlast AucvwT of ACT1vtTY LOCatso4 0s agtgast L.IJ @ L.JJ@l NA l l NA l i s > . . ,, . penso e,gt guPCaunts .. esvu.Em Tvrt otsC aerTiom i > 101010 l@LZJ@l . NA l #.' reasoa.=e'L s.uNa'ias - ' ' " ~ E -- otscairfio*h . e.vu.in 101 Ol0 l@l NA i a g , , . . .. n . . Loss os om oawaGE To FaCauTV .. Twg oi3CairTeom ,lD. L2J@l "A ' I - . .. ..... "* "t'."c .... _ @ . , ' a cvsaom- I?Iel l N[81 NA ,, ) l l l l l l l l l l l lJ t e i se .. ..

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, . * , .

JGKepple r. Administrator ' p Pelisades I'lant. I LEP. 83-74 < - - , December 9, 1983 l . During the current refueling outage, all twenty-feur (24) main steam relief velves were remoyed and cent off-site for surveillance testing par r Surveillance Pf6cedure R!!-29. The results of the."as found" testing indicata , that fourteen (14) valves lif ted af. test pressures in excess of ths upper , li:iit specified in TS .3.1.7.c. The maximum pressure at which a valve lifted

was 1147 psig and the minteum pressure in excess of the TS limit was 1G40 psig. ' a As described ih F5/S Chapter 4 3.4, the design at Palisades is such that the hain steam relief valves are divided into three groups, each group having a l differe,.nt lif t setting. The perfomance of the surveillance test resulted in , a total of twenty-three (23) relJef valves lif ting at pressures in ciccess of the upper limits of the FSAR and surveillance test acceptance criteria for eveh group; Fourteen (14) of thei;e valves were also in excess of the upper lie,it impose'd by TS 3,1.7.c as described above. The cause is believed to have resulted from adjustments made during the

previous refueling cutage to the valve's blevdown ripg and subsequent to the _ final lif t setting adjuste:ent which was made at that time. Adjustments to j the valve's blesado.en. ting uere pernitted by pror.edure. Adjustments to the ' blevdown ring were not anticipated to have an effect on the lif t pressure

value. ' . The test proceidrs will he re;riecd to probibit any adjustments to the relief - valve blowdown ring prior to "as found" testing or subsequent to "as left" testing. ' < . ' . t d e 40 e t OC1283-00048-NLO2 - -_ .. . -.. . .- . , }}