ML20214H160
| ML20214H160 | |
| Person / Time | |
|---|---|
| Site: | Fort Calhoun  |
| Issue date: | 05/20/1987 |
| From: | Gagliardo J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | Andrews R OMAHA PUBLIC POWER DISTRICT |
| References | |
| NUDOCS 8705270293 | |
| Download: ML20214H160 (51) | |
See also: IR 05000285/1987008
Text
{{#Wiki_filter:MAY. t 0.1967 . . In Reply Refer To: Docket: 50-285 Omaha Public Power District ATTN: R. L. Andrews, Division Manager- Nuclear Production 1623 Harney Street Omaha, Nebraska 68102 Gentlemen: This refers to the Enforcement Conference conducted in the NRC Region IV office on May 14, 1987, with you and other members of your staff and Region IV staff members to discuss the findings of the NRC inspections conducted during the periods March 23-27, 1987, and April 6-10, 1987, which were documented in our NRC Inspection Reports 50-285/87-08, dated May 8, 1987, and 50-285/87-05, dated May 8,1987, respectively. The subjects discussed at this meeting are described in the enclosed meeting sumary. It is our opinion that this meeting was extremely beneficial and provided a better understanding of the concerns identified during the inspection. In accordance with Section 2.790 of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations, a copy of this letter will be placed in the NRC's Public Document Room. Should you have any questions concerning this letter, we will be pleased to discuss them with you. Sincerely, Original Signed By E. H. Johnsen J. E. Gagliardo, Chief Reactor Projects Branch Enclosure: Attachment - Meeting Sumary cc w/ enclosure: W. G. Gates, Manager Fort Calhoun Station P. O. Box 399 Fort Calhoun, Nebraska 68023 k 4[6 PI r 1 C:j C: RPMullikin:cs DR- ter JE liardo , j 5/) 87 5/R/87 5/ W87 [ 8705270293 870520 PDR ADOCK 05000285 ' O PDR E
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- . Omaha Public Power District -2- f ' Harry H. Voigt, Esq. . LeRoeuf, Lamb Leiby & MacRae 1333 New Hampshire Avenue,Jni - Washington, D. C. 20036 Kansas Radiation Control Program Director ^ Nebraska Radiation Controi Program Director bec to DM8 (IE45) bec distrib. by RIV: . ^ RPB RRI R.D.~ Martin, RA' RPSB SectionChief(RPB/B) .. MIS System RSTS Operator- RIV File -DRSP < RSB ' Project Inspector,- RP8 D.' Weiss,.RH/ALF R. Hall 4 i 4
. _ _ _ _ _ _ _ _ - _ _ _ _ _ _ - _ _ _ _ - _ , . .. Attachment Omaha Public Power District May 14, 1987 Meeting Summary Licensee: Omaha Public Power District (OPPD) Facility: FortCalhounStation(FCS) License No.: DPR-40 Docket No.: 50-285 Subject: Enforcement Conference Concerning NRC Inspection Findings (NRC Inspection Reports 50-285/87-05and50-285/87-08) On May 14, 1987, representatives of OPPD met in Arlington, Texas, with NRC Region IV and NRR personnel to discuss the findings documented in the two NRC inspection reports dated May 8, 1987. The attendance list and licensee presentation are attached. The meeting was held at the request of the NRC, Region IV. The NRC discussed the generic implications of the inspection findings in the areas of welding and maintenance activities. The licensee discussed the concerns and stated their views and any corrective action proposed or accomplished. Enclosures: 1. Attendance List 2. FCS Presentation
. . . . _ _ _ . - _ _ _ _ - _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ . . Enclosure 1 Enforcement Conference Attendance List - Region IV Omaha Public Power District NRC Attendees: R. E. Hall, Deputy Director, Division of Reactor Safety and Projects, RIV J. E. Gagliardo, Chief, Reactor Projects Branch, RIV D. R. Hunter, Chief, Project Section B, Reactor Projects Branch, RIV D. A. Powers, Enforcement Officer, RIV R. E. Ireland, Chief. Engineering Section, RIV P. H. Harrell, Senior Resident Inspector, Fort Calhoun Station E. B. Tomlinson, Project Engineer, NRR, HQ J. R. Boardman, Reactor Inspector, RIV L. D. Gilbert, Reactor Inspector, itIV 1. C. I ci't t reri, Ft otter Insrettor, RIV F. F. l'ullikin, Froject Inspector, RIV Licensee Attendees: R. L. Andrews, Division Manager, Nuclear Production, Fort Calhoun Station K. J. Morris, Division Manager, QA and Regulatory Affairs R. C. Liebentritt, Division Manager, Engineering M. E. Eidem Jr. , Department Manager, Generating Station Engineering (GSE) - Mechanical S. K. Gambhir, Section Manager, GSE J. J. Fisicaro, Supervisor, Nuclear Regulatory and Industry Affairs T. J. McIvor. Supervisor, Technical M. R. Core, Supervisor, Maintenance J. L. Skiles, Senior Quality Project Engineer, Sergeant and Lundy _ _ _ _ _
.< . ENCLOSURE 2 . - i PROCEDURES UPGRADE PROGRAM OBJECTIVES e IMPROVED TECHNICAL CONTENT OF ALL OPERATING MANUAL PROCEDURES. e ESTABLISH CONSISTENCY IN LEVEL OF DETAIL AND FORMAT FOR EACH PROCEDURE TYPE. e INCORPORATE HUMAN FACTORS INTO ALL PROCEDURES. e VALIDATE PROCEDURES AGAINST DESIGN DASIS. .
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~= = ~ . - - - . _ _ - - . . _ - ~ _ _ - . - . -. . . _ -. . -_~ . . . - _ - _ . - e , e i PROCEDURES UPGRADE PROGRAM , , APPROACH ' , e DEVELOP PROCEDURES WRITERS' GUIDE TO INCORPORATE INPO, NRC AND INDUSTRY " GOOD PRACTICES". < ' PROVIDE PRELIMINARY DRAFT OF GUIDE TO ALL PERSONNEL TO e BE USED AS INTERIM GUIDANCE. e ASSIGN A MULTIDISCIPLINARY TEAM OF OPPD PERSONNEL TO CONDUCT REVIEW AND REWRITE OF THE OPERATING MANUAL. ~' i .
o ESTABLISH A PROGRAM PLAN AND SCHEDULE FOR A STRUCTURED REVIEW OF EXISTING PROCEDURES AGAINST THE WRITERS' GUIDE CRITERIA AND REVISION OF THE PROCEDURES AS NEEDED. 4 l 1
e UPON COMPLETION OF THE DESIGN BASIS RECAPTURE PROJECT, l. ALL PROCEDURES WILL AGAIN BE REVIEWED AND REVISED AS , NEEDED TO ENSURE COMPLIANCE. t ! ! 1 1 i
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. . . .. . PROCEDURES UPGRADE PROGRAM e WRITER'S GUIDE FOR MAINTENANCE PROCEDURES WILL BE REVISED TO ENSURE TORQUE REQUIREMENTS OR OTHER MEANS OF ASSURING CORRECT TENSIONING ARE SPECIFIED FOR CQE FASTENERS WHERE APPRCPRIATE. ~o ALTHOUGH CURRENTLY INCLUDED IN THE WRITERS' GUIDE,.THE- NEED TO DEFINE ACCEPTANCE CRITERIA FOR ANY READINGS OR MEASUREMENTS TAKEN~WILL BE EMPHASIZED. e ALL TEST EQUIPMENT TO BE USED WILL BE REQUIRED TO INCLUDE DEFINITION O.? ACCEPTABLE RANGES FOR USE. e MEGGERING EQUIPMENT WILL BE SPECIFICALLY ADDRESSED IN'THE WRITERS' GUIDE FOR MAINTENANCE PROCEDURES WHERE APPROPRIATE. > i ! i i !
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. . . . PROCEDURES UPGRADE PROGRAM NEAR TERM SCHEDULE e APRIL 30, 1987 - COMPLETED OP/OI WRITERS' GUIDE. IMPLEMENTED WRITERS' GUIDE AS INTERIM GUIDANCE - FOR ALL PROCEDURES. e MAY 31, 1987 - COMPLETE WRITERS' GUIDES FOR ALL OTHER OPERATING MANUAL PROCEDURES (MP, ST, RP, EPIP, ETC.). ESTABLISH PROCEDURE REVIEW / REWRITE TEAM. - e JUNE 30, 1987 - FORMALLY IMPLEMENT ALL GUIDES AFTER INCORPORATING COMMENTS. COMPLETE SCHEDULE FOR FULL REVIEW AND REVISION OF - OPERATING MANUAL l
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.- .. - . . _ . . - , . . . . . . FORT CALHOUN STATION PLANT LIFE EXTENSION PROGRAM e BOTH FINDINGS RELATE TO ESTABLISHING AND MAINTAINING A PROGRAM TO ADDRESS DESIGN LIFE OF SPECIFIC COMPONENTS e OPPD HAS INITIATED A PLANT LIFE EXTENSION (PLEX) PROGRAM THAT WILL ESTABLISH A MECHANISM FOR ADDRESSING THE PLANT EQUIPMENT THAT IS SUSCEPTIBLE TO AGING DEGRADATION. THE PROGRAM WILL RESULT IN AN INTEGRATED APPROACH-TO , CRITICAL EQUIPMENT MAINTENANCE AND REFURBISHMENT. e PART OF THE LOGIC TO BE BUILT INTO THE PLEX PROGRAM WILL BE A DETERMINATION OF THE ACCEPTABILITY OF CORRECTIVE l VERSUS PREVENTIVE MAINTENANCE FOR CRITICAL COMPONENTS. i THIS LOGIC IS BASED ON THE SAFETY AND AVAILABILTY IMPACT OF COMPONENT FAILURE.
i e INDUSTRY AND VENDOR INFORMATION WILL BE USED TO DEFINE i PREVENTIVE MAINTENANCE STRATEGIES FOR EACH COMPONENT. e GOAL FOR END OF 1987 IS TO HAVE DEFINED ALL EQUIPMENT THAT MUST BE INCLUDED IN THE PLEX PROGRAM. . _ _ . . . . . - . . . . . . . . . . . . ._. _ . _ _ _ - _ _ . _ .
. ,NL ., .. .- , FORT CALHOUN WELDING PROGRAM , I. -History A. Procedures were adapted from construction procedures. _ B. Original basis - high quality welds, but limited number. C. -Centralized nuclear / fossil welding program ~ developed 1977. D. Extensive modifications, especially structural,'showed program needed improvement. E. AWS procedures added to program in 1986. 'II . 1985 SS0MI and QA audit findings A. Workmanship - generally adequate, but could be better. B.. QC inspections - greater consistency needed among inspectors.- C. QC inpsection forms required additional detail. D. Welder qualification and performance records needed improvement. . III. Corrective actions for SS0MI and QA audit findings A. . Maintenance training program. B. QC inspector training - permanent employees and contractors. C.. Revised QC inspection log, documentation forms. D. Upgraded records program. IV. Welding program revisions - 1986 ' . Developed separate Standing Order (G-12A) to address just welding. - including A. documentation requirements. -B. Centralized weld rod issue. . C. Added additional inspection requirements. D. Added weld design data forms. . V. 1987 Welding Inspections . A. Les Gilbert - 3/87 B. John Tetreault - ANI/ANII - 3/87-4/87. C. Hartford steam boiler ANSI N626.1 and ASME Section XI, Division 1 4/87. D. OPPD Quality Assurance audit of welding program 4/87.
. . .. .- E. Summary of problems identified. 1. Weld procedures should have additional ' detail - code references, materials, etc. 2. Qualification records are scattered, maintenance of qualification is difficult to verify. 3. Additional detail is needed in QC inspection records - code references, etc. F. Basic ' reason for problems - lack of awareness. VI. Generic program improvements (in progress) 'A. . Additional Technical review and revision of ASME welding procedures. B. Additional Technical review and revision of AWS welding procedures. C. Automated welder qualification documentation program. - ready for data entry D. Additional Technical review and revision of NDE procedures. VII. Specific responses to Inspection Reports 87-08 and 87-14 A. . elder qualification records > W . 1. Complete review of all available documentation back to 1973 - 8 man weeks. 2. One safety-related weld made by a welder whose certification had lapsed. 3. Evaluation to be completed prior to restart. B. WPS-51 thickness range - to be corrected by revision to program. . C. F1 vs F4 filler metal - believed to be a typographical error - to be corrected by revision to program. - D. Postweld heat treatment for WPS-1 to be corrected by revision to program. PWHT will not be used unless it is adequately addressed in a procedure. E. Completion of MR-81-180 An engineering analysis has been performed to address the strength requirements of as-built configuration. A flare-bevel procedure has been developed and qualified using the same techniques that were used to make the field welds. Field welds will be reinspected and this data will be used to provide additional support for the justification . of the existing welds. F. Pentrameter placement on radiography of EFWST OPPD believes we are on solid technical ground, position is supported by ANI. Nevertheless, all radiography of repair welds since inspection 87-14 has been done with the penetrameter on the source side and the first two repair welds have been re-examined in this manner. q- D . - ,
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-, s . . . G. Hydrostatic test pressure. Has been revised.to 55 psig (1.1 X design pressure) per ASME Section XI. Note: operating pressure is 0.5 psig N ver head pressure. 2 VIII. 1987 Refueling Outage As a result of 550MI, strong emphasis has been placed on high quality welds and inspections. Quality has been demonstrated on jobs such as replacement of pressurizer spray valves and piping, installation of RCS root- valves and replacement of HCV-247 and HCV-248. The efforts have also extended to structural welding on such modifications _as the inverter _ bypass transformers and the storage platform in the containment. OPPD does not believe that the problems identified are serious enough to affect restart of the unit. They are largely documentation problems and - not problems with weld quality. The problems, however, will be corrected. IX. Corrective action schedule A. Confirmatory reviews of welding and NDE in progress. B. Procedure revisions to be in place by 9/1/87. C. Automated qualification records program under development. - ready for data entry D. Welder qualifications to be updated and records system fully operational by 10/1/87 (Revised welding procedures must be in place first). X. Safety related welding A. Will be done by qualified people using qualified procedures. B. Special attention during -interim until all upgrades are in place. i . i e ! ,
c' 1 , . . EMERGENCY FEEDWATER TANK AND OTHER EATON TANKS I. Discovery A. Planned to sandblast and recoat. B. High crowns and rough welds on inside of tanks- concerned about coating adhesion. C. Decided to grind welds flush - MT to verify no surface or wear-surface defects. D. MT showed substantial indications. E. RT of all tanks welds to determine extent of repairs required. II. Design conditions A. ASME Section VIII, Division 1, 1965. B. Base metal A 285 grade C plate, nominal thickness 1". C. Weld metal 1. Inside - manual using Lincoln Shield Arc 85 rod (equivalent to 7010-A1). 2. Outside - submerged arc multi-pass after air arc gouge to root pass. D. Design pressure 50 psig - hydrostatically tested to 75 psig. E. Seismic joint efficiency - 85% - partial RT F. Built by Eaton Metal Products, 1969. over head pressure III. Operating conditions - 0.5 psig N2 IV. Probable cause and extent of defects A. Cracks, slag inclusions, lack of fusion. B. Approximately 40% of total weld requires repair. C. Probable cause - contributing factors 1. Use of Shield Arc 85 rod without preheat - shrinkage. 2. Improper cleaning of copper deposits from arc gouge - leads to lack of fusion. 3. Poor workmanship. .
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. D. Metallurgical analysis - brittle fracture, no fatigue (not service - induced) V. Repair procedures A. Grind or arc gouge to remove defects. B. QC inspection to verify cleaning, MT to verify that defect has been removed. C. Weld repair using E7018 rod, 200 F preheat. D. MT and RT following repair. , E. Hydro to 55 psig following completion of repairs. -F. EFW tank is part of our ISI program. Examined under ASME Section XI. Repaired to ASME SectionIII, Subsection ND 1983, summer 1984. G. Repair procedure approved by ANI. VI. Eaton tanks A. Survey performed to determine what tanks were constructed by-this manufacturer, followed by failure assesment. B. EFW tank is most critical. C. Diesel generator. fuel oil tank. 1. Cleaned and inspected 1987 - no readily apparent problems. 2. Petro-Tite leaks test performed - ok. 3. Buried tanks - soil support. 4. Engine and wall-mounted day tanks. D. CCW tank - 1. Operating pressure is a fraction of design (20%). 2. Fluid is clean, non-corrosive. 3. Hydrotest to 55 osig in 1983. 4. RW is installed back up. VII. General considerations on return to operation A. Catastrophic failure is unlikely. ' B. Leaks are detectable. ' C. Leaks can be dealt with - commercial consideration, not a nuclear safety problem. --
.. .. .. . - -_ - _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ POTENTIAL VIOLATION , g FAILURE TO' IDENTIFY AND RETRIEVE RECORDS 3.b.2 THE NRC INSPECTOR REQUESTED THE ORIGINAL DESIGN BASE CALCULATION AND ORIGINAL INSTALLATION RECORDS (" CODE DATA PACKAGE") FOR THE MS SAFETY RELIEF VALVE LINE FLANGE JOINT BOLT STRESS LEVEL. THE LICENSEE WAS UNABLE TO RETRIEVE THESE RECORDS. . . . VIOLATION OF 10 CFR 50 APPENDIX B CRITERIA XVII. 3.c.2 THE NRC INSPECTOR REQUESTED ORIGINAL DESIGN BASE CALCULATIONS AND INSTALLED RECORDS FOR THE PRESSURIZER SRV LINE FLANGE JOINT BOLT STRESS LEVEL AND BOLT TORQUE. . . . VIOLATION OF 10 CFR 50 APPENDIX B CRITERIA XVII.. 3.d.3.a THE FAILURE OF THE LICENSEE TO IDENTIFY AND RETRIEVE ORIGINAL DESIGN CALCULATIONS FOR BLADE ANGLES ON FANS VA-3A, VA-38, VA-7C, AND VA-7D IS ANOTHER EXAMPLE OF POTENTIAL VIOLATION (285/8705-02), FAILURE TO MEET 10 CFR 50, APPENDIX 8, CRITERION XVII. . . . .. . .. . _
. . .-. --. . _ - - . .. -. . . . - - . . .. - - - - _ v > > <a , , . . , + b b' 4 i ! . .. r l- SUMMARY ! j 1. DESIGN BASIS RECORDS ARE NOT EASILY RETRIEVABLE. 2. TORQUE VALUES FOR THREADED FASTENERS ARE NOT TRACEABLE TO THE DESIGN BASIS DOCUMENTS.
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SHORT TERM CORRECTIVE ACTIONS: PLANT STAFF HAS DEVELOPED AN INTERIM PROCEDURE FOR VERIFYING TORQUING REQUIR MENTS FOR SELECTED SAFETY RELATED EQUIPMENT WHICH WERE DISASSEMBLED AND/0R .
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. l, LONG TERM CORRECTIVE ACTIONS
.. 1. REVIEW MAINTENANCE PROCEDURES TO VERIFY THAT APPLICABLE DESIGN DRAWINGS CODES AND/0R VENDOR MANUALS ARE REFERENCED ON THE MAINTENANCE PROCEDURES. 2. REVISE MAINTENANCE PROCEDURES TO INCLUDE INSTRUCTIONS THAT ONLY ONE FOR ONE FASTENER REPLACEMENT IS ACCEPTABLE. 3. TORQUE VALUES SPECIFIED SHALL BE CONSISTENT WITH THE TYPE OF HARDWARE PER EPRI PUBLICATION AND DESIGN DRAWINGS AND APPLICABLE CONSTRUCTION CODE REQUIREMENTS. 4. GSE REVIEW APPLICABLE DESIGN DRAWINGS TO ENSURE THAT ACCURATE FASTENERS DATA IS AVAILABLE ON DESIGN DRAWINGS REFERENCED IN MAINTENANCE PROCEDURES. (PIPE SUPPORTS, PIPING IS0 METRICS, SEISMIC SUPPORTS FOR MECHANICAL AND ELECTRICAL EQUIPMENT.) 5. DEVELOP THE FOLLOWING DOCUMENTS TO SUPPLEMENT THE AB0VE ACTIONS: - CRITERIA FOR USE OF FASTENERS (SPECIFY ACCEPTABLE FASTENERS, APPROVED . LUBRICANTS, STRESS VALUES, TORQUE REQUIREMENTS, ETC.). - DESIGN GUIDE - DISCUSS APPLICATION OF THE CRITERIA. - FC STANDING ORDER ON FASTENERS TO DOCUMENT REVIEW PROCESS. SCHEDULE THE AB0VE ACTIONS ARE PLANNED TO BE COMPLETED BY 6/88. 1
4- A. .. .. P0TENTIAL VIOLATION 50-285/8705-14 FAILURE TO USE REQUIRED LUBRICANT IN ELECTRICAL EQUIPMENT QUALIFIED (EEQ) LIMITORQUE VALVE OPERATORS. THE LICENSE INDICATED THAT HCV-383-4-0, HCV-347-0, HCV-348-0, HCV-331-0, HCV-383-3-0, AND HCV-333-0 LIMITORQUE OPERATORS CONTAINED A MIXTURE OF NEBULA EP-1 AND MARFAK GREASES WHICH THEY CONSIDERED QUALIFIED EVEN THOUGH SUCH PRACTICE CONTRADICTED THE SPECIFIC REQUIREMENTS OF THE APPLICABLE LIMITOROUE- TYPE SMB INSTRUCTION AND MAINTENANCE MANUAL, BULLETIN SM81-828. THE DOCUMENT USED AS JUSTIFICATION WAS BOLT AND ASSOCIATES LETTER DATED JUNE 17, 1986, " MIXING MARFAK WITH NEBULA EB OR (SUN OIL COMPANY) PRESTIGE 50 EP."
- _ . . . . , . THE LETTER BEGINS WITH A STATEMENT THAT NO PROBLEM EXISTS WITH LIMITORQUE OPER- - ATORS BECAUSE OF MIXING, SINCE INCOMPATIBILITY IS LIKELY TO RESULT IN " SOFTEN- ING" ( A DE-HYDROLYZATION OR DE-SAPONIFICATION OF THE GREASE INCREASING ITS ' FLUIDITY). THE LETTER STATES THAT THIS WOULD BE NO PROBLEM SINCE THE GREASE IS CONTAINED IN THE GEAR 80X. ADVERSE CHEMICAL REACTIONS (BEARING CORROSION. ETC.). REDUCTION OR LOSS OF EXTREME PRESSURE (EP) CHARACTERISTICS. OR SEPARA- . TION OF OIL FROM THE MIXTURE. ALL OF WHICH MAY RESULT FROM INCOMPATIBILITY OF
THE GREASES. WERE NOT ADDRESSED. , 1 , l 1 , t ! .
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6 $ THE LETTER SUMMARIZES WITH A PARAGRAPH WHICH STATES: "I DO NOT WISH MY COMMENTS ON MIXING GREASES TO BE CONSTRUED AS END0RS- ING SUCH A PRACTICE. I AGREED WITH LIMITORQUE (DULLETIN SMBL-80) THAT THIS SHOULD NOT BE DONE AS A MATTER OF POLICY. IT IS NOT A GOOD IDEA, PARTICULARLY IF THE GREASES MIXED INVOLVE DIFFERENT GELLING AGENTS, AS IS TRUE WITH THE SITUATION AT HAND. THE BEST PRACTICE IS TO PICK AN APPROVED GREASE (NEBULA IS THE ONLY ONE APPROVED FOR EVERYTHING) AND STAY WITH THIS PRODUCT DOWN THE ROAD. IF HORE THAN ONE SUPPLIER IS DESIRED OR AS OTHER PRODUCTS ARE QUALIFIED, IT WOULD KEEP WITH HATE- RIALS CONTAINING AT LEAST THE SAME GELLING AGENTS." MARFAK AND NEBULA EP GREASES HAVE DIFFERENT GELLING AGENTS. LIMITORQUE HAS STATED THAT QUALIFICATION OF THEIR OPERATORS IN CONTAINMENT IS CONTINGENT UPON THE SOLE USE OF EXXON NEBULA EP GREASES. FAILURE TO USE THE REQUIRED GREASE IS A POTENTIAL VIOLATION OF 10 CFR 50.49 (285/8705-14). i ' v.* - - - - . - . . - - - - - - - . - . . - - - . . . - - . . . - - - - . . . . - . . - . . - . . . . _ _ . _ _ ,
_ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ . . + '. / '. Belt & Associrt:s Consulthg Services Lutsticants . Lubrication . Radiation Effects j June 17, 1986 Robert O. Ilott, Ph.D. Mixing Marfak with j Nebula EP or Prestice 50 EP Hr . J . E . Thoma s Duke Power Company Design Engineering Department Box 33189 - Charlotto, North Carolina 20242 l Dear Jim j , ' 'You ask if a problem exists with Limitorques as a' result of () the above. _The simpio answer is no, and I will detail the _ reasons here. ~ Incompatibility due to mixing or radiation and thermal stressos are likely to result in softening of the grease mixtures. This softening creates increased possibility of leaks away from ' parts to be lubricated. This is no concern with Limitorques because the lubricant is contained in a sealed gear caso. A grease or an oil is quito satisfactory in such equipment. A grease is specified just to reduce leakage through seals. The (base oil and additives that perform the lubrication function (3) ! will do their job irrespective of the sof tness of the lubricant (in the gearboxes. You can satisfy yoursoif on incompatibilities (avon though.I do not believe there is a problem) through periodic inspection of ' the lubricants in the gear cases. Visual observation should suffico, but representative samples can also be taken for analy- m sin. For direct observation, uso a spatula and poke it into the W ( grease to work the lubricant around to judge conslutency. This ' should be after having dono the same thing with the fresh prod- uct to become familiar with the " feel" of the material. Look for any leakage through seals, as well. Such leakago loavos behind increased concentrations of gelling agent and a hardor groano mixture. If one has to add say 15%. as mal.o-up due to leakage, the Limitorque should be removed from service for repair. The groano npecified by Limitorque for use insido containment is Exxon Nebula EP. This iri a calcium-complex-gelled product. The Texaco Marf ak lu a nodium noap-golled greane. I have no $$ Cullm!cn l'k. Rd. . San Rafael, CA 94901 . (415) 453 6095 . - -. - - . j
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e a , a. E. Thomas -2- June 17, 1986 ' / / data directly on these two products. However, data are avail- able on similar materials with the same two gelling agents (F. S. Meade, " Compatibility of Lubricating Greases," Report No. 61-2132, Rock Island Arsenal Laboratory, Department of the Army, 1961). No appreciable incompatibility showed up on simple mixing. The Sun Prestige 50 EP grease is gelled with lithium hydroxy stearate. No direct data are available on it either with mix- tures of the Texaco grease. However, similar greases showed no difficulty in the Rock Island Arsenal study. / I would expect irradiation to cause an additional amount of 4 I softening, but one would have to go above 108 rads to induce a (greateffect--ahighdosefornormalsituations.hasqualifiedN Again, though, I softening is no problem with Limitorques. Limitor rads and 0 140 F ambient with a transient of 3400F. It also qualified the Sun product to 2 x 107 rado at 1200F ambient and 2500F transient. I do not wish my comments on mixing greases to be construed as endorsina such a practice. 1 agree with Limitorque (Bulletin SMBL-80) that this should not be done as a matter of policy. It is not a good idea, particularly if the greases mixed involve g dif ferent gelling agents, as is true with the situation at hand. The best practice is to pick an approved grease (Nebula is the only one approved for everything) and stay with this product down the road. If more than one supplier is desired or as other products are qualified, I would keep with materials containing at least the same gelling agents. You have our propublication draft or piece, " Radiation Effects on Lubricants." This is boing published by EPRI. It is designed for use by engineering and design personnel as an education paper. Jim Carroll and I are working on a second piece- " Lubrication in Nuclear Power Plants." This is for operations personnel and details various lube applications and suppliers of products for these. It also addresses such application problems as the con- sequences of mixing greases. We expect this publication to be out as another EPRI report in the Fall of 1986. 5 I hope this information will serve your needs. Please call if I can be of further help. Very truly yours, $ .)0 Y ~ 0 { . cc: Mr. R. N. Kubik, EPHI Mr. J . G. Carroll L
- ~
LIMITORQUE LUBRICATION DISCUSSION'
. . BACKGROUND:
UP UNTIL AUGUST OF 1986, OPPD'S POSITION ON LIMITORQUE LUBRICATION WAS THAT TEXAC0 MARFAK GREASE ALONG WITH LIMITORQUE QUALIFIED EXXON EP-0, AND A MIX- .TURE OF MARFAK AND EP-0 WERE ADEQUATE FOR USE IN VALVE _0PERATORS.
THE MARFAX WAS JUDGED ADEQUATE BASED ON INFORMATION SUPPLIED BY TEXACO AND THE MIXTURE WAS CONSIDERED ADEQUATE BASED ON INFORMATION WHICH TOLD OPPD TO MIX THE GREASE AND SEE IF IT SEPARATED, WHICH IT DID NOT. (LIST REFERENCE AND SUMMARIZE) MIXING'IS BELIEVED TO HAVE OCCURRED IN 383-3 AND 383-4.* THIS STANCE WAS
BASED ON THE ANALYSIS WHICH OPPD BELIEVED TO BE ALLOWED UNDER THE D0R GUIDELINES. (NEED COPY OF D0R GUIDELINES)
OPPD HAD INFORMED THE NRC EARLIER IN THE 1984 TER MEETING RESPONSE THAT- MARFAK GREASE WAS CONSIDERED QUALIFIED.
ON AUGUST OF 1986, OPPD LEARNED THROUGH INFORMATION SUPPLIED ON TVA AND DUKE POWER STATIONS AUDITS THAT OPPD'S POSITION ON LIMITORQUE LUBRICANTS SHOULD BE RE-EXAMINED.
- EXXON EP-0 WAS CONSIDERED TO BE THE PRIMARY LUBRICANT.
E ', .
BASED ON INFORMATION SUPPLIED BY DUKE POWER, IT WAS LEARNED THAT MIXING IS NOT A GOOD PRACTICE AND THAT THE MARFAK 2 ANALYSIS MAY BE INADEQUATE. TO ENSURE THAT NORMAL OPERATION COULD CONTINUE AND COULD BE CONSIDERED
SAFELY, A JC0 WAS PREPARED AND DOCUMENTED IN GSE-FC-86-822.
GREASE CHANGE OUT DURING THE 1987 REFUELING OUTAGE WAS RECOMMENDED. TO DATE, NEARLY ALL OF THE GREASE HAS BEEN CHANGED OUT INCLUDING 383-3 AND
383-4.
DISCUSSION WITH PLANT MAINTENANCE INDICATED THAT NO DAMAGE TO THE GREASE AND BEARINGS HAS OCCURRED WITH ANY OF THE GREASE CONFIGURATION.
IN ADDITION, THE GREASE THAT WAS FOUND IN 383-3 AND 383-4 LOOKED IN GOOD CONDITION. THE GREASE WAS FOUND TO BE OF A "DIFFERENT COLOR" DUE TO MIXING, BUT SHOWED
NO SIGNS OF SEPARATION OR HARDENING.
MOV TESTING BY MOVATS INDICATED THAT MOV VALVE OPERATORS AT FCS WAS NOT BEING IMPACTED BY SUCH THINGS AS LUBRICANTS SUBSTANTIATING OPPD'S BELIEF THAT LUBRICATION WAS ADEQUATE.
. . .
A MAY 11, 1987 CONVERSATION WITH EPRI'S LUBRICANT CONSULTANT DR. ROBERT 0. BOLT, INDICATED THE FOLLOWING: - THERE SHOULD BE NO CHEMICAL REACTION ONLY A POSSIBLE CHANGE IN THE GELLING AGENT COULD OCCUR. IF THE GREASE HAD NOT HARDEFED OR SEPARATED IT SHOULD BE OK - WHICH IT APPEARED TO BE. - THE BEST WAY TO DETERMINE DAMAGE VIA LUBRICATION PROBLEMS, WOULD BE TO INSPECT. THE GREASE CHANGE OUT PLUS MOVAT TESTING SHOWED NO GEAR OR BEARING PROBLEMS. - COLOR IS NOT A PROBLEM - IT IS COSMETIC ONLY. l
DURING EARLIER REPLACEMENT OF MARFAX WITH EP-0 IN THE 1983-1984 TIME FRAME, THERE WAS NO LUBRICATION DAMAGE QUESTION RAISED, WHICH FURTHER SUBSTANTIATED OPPD'S JUDGMENT WHICH DETERMINED THAT A JC0 COULD BE SUPPORTED. i I I - _ - - _ - . . - - . . . - . . - _ _ . - , . -__ . - . _ . - _ - . . - _ . . - _ , _ - . -
- '
" . . CONCLUSIONS 4
IN 1985, BASED ON GOOD FAITH, OPPD CONCLUDED THAT MIXED GREASES WERE ACCEPT- ABLE PER D0R GUIDELINES.
AFTER LEARNING THE RESULTS OF DUKE POWER AUDIT, OPPD TOOK PROMPT ACTION TO ANALYZE THE SITUATION AND PREPARED A JCO.
DURING 1987 OUTAGE GREASES IN ALL LIMITORQUES WERE REPLACED WITH EP-0 GREASE.
MOVAT TESTING HAS VERIFIED THAT NO DAMAGE WAS CAUSED BECAUSE OF MIXED
! ! GREASE. ,
6 9 UNRESOLVED ITEM (285/8705-13) (!!SJ81 CATION OF CONTAINMENT COOLING FAN MOTORS AND LIMITOROUE OPERATORS THE LICENSEE WAS LUBRICATING RELIANCE MOTORS IN CONTAINMENT ON AN 18-MONTH (REFUELINC OUTAGE) IN LIEU OF 3-6 MONTH PERIODICITY, AND HAD USED MARFAK LUBRICATION IN LIEU OF NEBULA EP-0 IN LIMITORQUE OPERATORS IN CONTAINMENT. THIS WILL REMAIN AN UNRESOLVED ITEM PENDING FURTHER REVIEW DURING A SUBSEQUENT INSPECTION (285/8705-13).
. . o . . CONTAINMENT FAN LUBRICATION VA-3A, 3B, 7C, 7D THE LUBRICATION FREQUENCY OF THE CONTAINMENT VENTILATION FAN MOTORS (VA-3A, 30, 7C, 70) IS BASED ON APPENDIX B, " GENERAL DESIGN COMMENTS FOR RELIANCE MOTOR . . .," 0F " SIMULATED ENVIRONMENT TEST FOR J0Y AXIVANE FAN / MOTOR FOR NUCLEAR CONTAINMENT FOR THE FORT CALHOUN NUCLEAR POWER STATION. . .," WHICH RECOMMENDS A MAXIMUM LUBRICATING FREQUENCY OF TWO YEARS. { ' THIS INFORMATION WAS REVIEWED BY S&L AS PART OF OUR 1985/1986 EEQ COMMITMENT TO REVIEW MOTOR MAINTENANCE IN THE EEQ PROGRAM TO CLOSE OUT THE 1985 INSPEC- TION REPORT ON OPPD'S EEQ PROGRAM. '
BASED ON THE AB0VE INFORMATION, A MAINTENANCE FREQUENCY OF EVERY REFUELING OUTAGE IS AD0PTED FOR LUBRICATION OF THE FAN MOTORS.
OPPD BELIEVES THAT 00R PRESENT LUBRICATION SCHEDULE IS ADEQUATE. . - - - - .
- - . - . _ - -. . . . - ._ _ _- --- _ . _ . . . . ' ' . . GSE-8-2-2 form I .f' PREPARED BY.
- '$ d s
l i ' ~ l CHECKED BY wd-/A t.
l APPROVED BY 9.,Jh _ SH. _L CONT. ON SH. F Rev. 10/85 l REY. di DATEgo/w _ MR No. l ' ' OMAHA PUBLIC POWER DISTRICT I , LGENERATING STATION ENGINEERING'
ELECTRICAL EQUIPMENT QUALIFICATION DOCUMENTATION FILE t EEQ H-08 1 5.0 MAINTENANCE REQUIREMENTS l EQUIPMENT: Reliance Fan Motors QUALIFIED LIFE: 40 YEARS MAINTENANCE REQUIRED TO MAINTAIN QUALIFIED LIFE: I Per the E the fan motors VA-3A, VA-38, val 7C,.[M.,Q. Analysis,S&LCQD-020062 d VA-7D' require 'relubrication of the. bearing..at a frequen i (c)',. of 2 years. ' Procedure.PM-EE-12 provides the direction to perform t t maintenance. ThTi{I. Program schedules the performance of PM-EE-12 for the~four tag ~ripKat~h.inininiumpequency.lof every outage. . PERIODIC TESTING REQUIREMENTS TO MAINTAIN QUALIFIED LIFE: ! None Required ADDITIONAL MAINTENANCE REQUIREMENTS: In S&L Letter No. CQO-026793 of January 3,1986 it is stated that there needs to be drainage path for moisture condensation in the conduits that , go to the fan motors. The conduits that carry the power feed to these 1 motors runs horizontally from the terminal boxes. The conduits that - - carry the power feed to the terminal box enter the terminal box from the bottom. This will provide adequate drainage. , i
i r .,-------wy-mg---g- w wre-,-,ugwe-+ pee,n+-9,%wes.-q+p-y gw gyn=w M w'59--g.,79*my- y. yegg- w-- em w e& t,- er--e,p-m--+ - + .-&--a wew ,-gww-w y ,ws, m- - -,
U V.U Us'sy 7 >.4 ,..l}jl[* J / - _C- tsti ro, Reliance Motor _ -- - n. ', E fi/;LOODY Celt. rfo COD-02006 2 Fan Motor Af ff; --- -- grmmner... L n ev. 00 oc:e 4-g-g 5 ; t ~* < - c ac o X s,f,t y- R r bt ed l i Non-Dfrty-RcSted Page 6 of 7 l , N.h gy . t f ,- ':%y.j, . OPPD %%l- Prepsred by Drte ]'.',QM Fort Ca1houn - Unit 1 Revicwed by Otte . I.] 7236-40 Equip. No. See page 1 ,, A Approef by Date . j %g-) . ' 4; T . . W '- . , 6) Chemical spray . )f: .. Per Reference 3, page 12 and Reference 2, page 4 the boric acid l
- m.
5000 PPM (2.5 pounds of boric acid in 500 pounds of water) [.~ ~ . injected into the chamber during accident environment performance y %" ]; , was l test. It envelops our requirements'of 2000 PPM Boron. . fd , [ 7) Submergence and Flood Level we -- ' , As per Electrical Equipment Qualification Manual, the level of f[. .-p.) MO 4. v flooding for containment is 1000.9'. The subject motors are located above the flood level (per SCEWs) and submergence is, h' '.$
- >"
- . 4
therefore, not applicable. 3) Operability ,' . p . 3- , - 1 x. V.8' functional operability of the motor is shown in the Accident Y' ' Y . ~,k The Environment Performance Test L 9 :t " (See Reference 2, pages 4 and 5, ( "j y Section 4.2. Since the motor was energized for the test, the i e'g,e operability of the moter is verified. I , f, )) Synergism , h,u, h.. w ' There is no known synergistic effect identified on the materials of the subject equipment. j'.h; AO . S- "'Y )) Maintenance and Surveillance fiMT '..'f'.hi. Re-ltibricate the motor bearing at a maximtrn of 2 years interva' ls b'id E ps recommended by the vendor (Reference 1, page 10)
- h
,i .) Main Steam Line Break (MSLB) Analysis y. , ,. : . MSLB analysis performed by the District indicates a temperature transient of 355*F in contain- .'- y
ment. This transient shows that the containment g temperature exceeds the predicted LOCA temperature of 305*F for a period of p f ' g~ JL5 s e c o n d s . g . g l,7 Since during the " Rapid Pressure Rise Cycles" testing motor was 1.. v, ., m- operated in the chamber at temperature at 400*F and with full ciectrical load the MSLB requirements are met. [ ~
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. i h r* Re1 lance Motor Cafe. No. COD- 0 2 0 0 6 2 j- c,,,,. r o, ' SARGENT% LUNDY Fan Motor R ev. 00 0.t. 4-8-85 r 3.~.,~...._ ~- c .-. .c w o X Safety-Related N on-Saf ety-R elated Pagt 1 of 7 OPPD Prepared hMghe[[jV# DateM'8'b_ f h Fort Calhoun - Unit 1 Reviewed [,hg[g M hy 04te /j - G - W 7 , 7236-40
- Equip. No. See below
Approved by 8//A/ Date //-/'- F - ,, r ~ l 1 [! Purpose g __ f Perform engineering evaluation and analysis to show that the components ( identifed below are environmentally qualified for use at Fort Calhoun p Unit 1 Nuclear Station. I Refererces 1)__ .Wyle. Labora_ tori,e_s , Report No . 26333-28, Thermal Aging _ Analysis ,of Containment Ventilation Fan Motors Manufactured by Rellance Electric, dateil June 22, 151i2. ~~ ' ' ~~ f ~ p 2) Joy Manfacturing Company Report No. FF-12521, Test Procedure for f Accident Environmental Testing of Fan for Nuclear Fueled Power = Generating Station, dated July 31, 1970 . 3) Joy Manufacturing Company Report No. X-377A, the Simulated ['. Environment Test for Joy Axivan Fan / Motor for Nuclear Containment, j dated September 3, 1970 p,j k 4) OPPD Interoffice Memorandum #GSE-FC-82-222, dated March 2, 1982.. /. 5) Letter from R. D. Schilz of Joy Manufacturing to M. Watson of - Stone & Webster with attachment, dated April 5, 1983. g Equipment Identification e Tag No. Name Serial No. Function Location j;. E VA-3A Motor 2X321793Al-CV Fan Motor Containment $ 2 " " VA-3B 2X321793A2-CV " " " " VA-7C 1X321793A2-CV
- I
" " 7A-7D 1X321793Al-CV o " $ h Assumptions 2 T o + - c: It is assumed that the non-metallic materials of motors for fans N C -h " VA-7A & 7B are same as those for fans VA-3A & B since both have the same insulation Class 'N'. ! $ N 5 9 '. S
C t O . i . -rI' .
, g , , REPORT NO. ~ .,. , im n==> scame suntsa svsnus oxw usnewoeinanows woecotAoun 10 , c, , 5.0 CONCLUSION The intent of this report was to identify materials susceptible to significant thermal aging degradation when subjected to the specified temperatures for the durations associated with each temperature. Based on a degradation parameter of 50 percent loss of dielectric strength as the critical property, all materials of the motor insulation system are not considered susceptible to significant degradation when evaluated for the time / temperature degradation effects of the environmental service conditions of Section 2.1. If the motor bearings are relubricated at__ maximum two. (2). year._ intervals as.. recommended._in Riisiinci 6l time /ttmperature_ aging _affects _ are ._not_ anticipated to significantly degrade the lubricating gr_ ease. . s , I i !
. M.u.= s scs. arc se me s a snn os c.aou, REPORY NO. -3 . .. - wisif9N OPtRAfloNE NoeCo FActuTV , ace p o 6.0 REFERENCES 1. Docket No. 50-285; Omaha Public Power District's Response to the USNRC Safety Evaluation Report on Environmental Qualification of Safety-Related Electrical Equipment at the Fort Calhoun Station; Enclosures I and 16. 2. Letter to Mike Capella (OPPD) from Jim Thompson (Wyle) dated April 27, 1982. Subject: Containment temperatures, Fort Calhoun Station, Unit 1. 3. Contact Report: Mike Capella (OPPD) to Bruce Vatthauer, Jim Thompson (Wyle) ' dated June 14, 1982. Subject: Containment ventilation motor (items VA-3A/3B) operating time requirements and plant specific levels for post-accident duration and environmental temperature. 4. Elements of Polymer Degradation, Leo Reich, et. al., McGraw-Hill Book Company, New York,1971, Library Code 256-80. 5. "lEEE Guide for the Statistical Analysis of Thermal Life Test Data,"IEEE 101-1972, Library Code 265-80. 6. " General Design Comments - Reliance Electric Co. Motor Fan Drive for Reactor Containment Building,_ Ventilation and CooIIiig sys, tern," Joy 'ManTificttfring i C91Dpany._, _ 7. " PYRE-M.L. Wire Enamel," E.1. duPont de Nemours & Company, Bulletin l'19 (Revision l'5), January,1977, Library Code 399-80A. 8. " Life Equations - DuPont's U.LrRecognized Insulation Systems," April 21,1979,and " Properties and Performance of Nomex Type 410 Aramid Paper," DuPont Bulletin No. NX-7, November,1977, Library Code 145-78A. 9. DuPont U.L. File No. E 39505, November 15,1968, Library Code 173-78A. 10. " Temperature Indices of Industrial Thermosetting Laminates," NEMA Pub. L15- 1969, March 19,1969, Library Code 001-78A. ' ! !. " Varnished Glass Cloth, Exremely Flexible Class 180C," Westinghouse Electric Corporation Technical Data No. 64-580, February,1979, Library Code 459-81. 12. " Thermal Stability of Electrical Varnish," April 30, 1954, Dow Corning Number CE50A, Library Code 371-80A. . - h , ! - I i . . _ -_ . _ _ _ _ _ . - - , _ . _ _ _ , , , - . . - _ , _ .- . _ ~ . . , _ , - , . . . - , _ . , _ . . . . - - . - . . --r .. _
' JOY M ANUFACTURING CO. PA E F NEW PHIL ADELPHIA, OHIO REPORT NO. X-377A - t. o e PREPARED BY CHECKED DY DATE SeDrember 3,1970 . Report On "Ihe , SIMULATED ENVIRONMENT TEST FOR JOY AXIVANE FAN / MOTOR FOR NUCLEAR CONTAINMENT - REFERENCE JOY MANUFACTURING CO. FF12521 . For FORT CALHOUN NUCLEAR POWER STATION OMAHA PUBLIC POWER DISTRICT FORT CALHOUN, NEBRASKA CUSTOMER: WALDINGER CORPORATION
Thru , i AMERICAN AIR FILTER COMPANY tOUISVILLE, KEN'IUCKY AAF P.O. No.7391-CN481-108 @ECTION 21), ' JOY AXIVANE FAN MODEL 60-30-1200(MM) NUCLEAR SERIAL NO. GF-13111 PART NO. 500722-49 ~ Incorporating a Motor of ', RELIANCE ELECTRIC CO. MANUFACTURE H FRAME 5008 SERIAL NO. 2X321793Al-CV . , RATED 460V/3 PH/60 CY FORTCALHOUN : SECTION 21 : UNIT VA 3A/B Sw. Dic k F eM E O i ? . ?.,3D - % 200 . P O m ae NPE$ . .. p-r,yww-w -- m -wy,y.t ,----v,,--eg we-- -w 3-- --w-- y- - -------------g---mx--m-w ,,m----- - - g.pw%y-- ,-g =g---=or- - - - * * ' y
. \\ - i . . ~ . 000106
f~ /144 ' . . . , . . . . . . . .'; .% }' NRWPHILADELPHIA DIVis/0N a: JOY MANUFACTURING COMPANY l 333 ECUTH S AOAOwAv P.O. e04 e38 '. teEW P tLA06 LPMlA.OM40 4*483 .g i ' . . - . t ' GENERAL DESIGN COMMENTS
.
- " RELI ANCE ELECTRIC COTMOTOR FOR FAN DRIVE . .; ~ ~ ~ ~ 70R a REACIOR_CQLfrlffMENT...BUIkqD[G ' f . - - $ VENULAU_0N AND COOL _QG_SXSJ,W
. I I & $ t.'. : - i.: W l . The following delineated conditions itere the basis for
- -
i .* _,-l L.' the motor / fan design specification: - . 8 JI ' s 1. Radiation. Maximum dosage of 10 Rads of
- '
Gamma Radiation during the lifa of motor. ' ' l f, - . Short time temperature during. hours duration, emergency mode ., !. ,) 2. ' of 3000 F. ambient for 3 to 4 f. then a gradual decay to 150 F. 8 ' - . 3. Vapor pressure of 80 psig during emergency mode. l4 -
4. Short time exposure to 100% relative humidity .I during emergency mode. With vapor droplets and
.n slightly caustic atmosphere. i i S. Nornal air pressures of 18.3 psia. ' 6. Normal exposure to 50% rc.1stive humidity, ' i 3 'at 125 to 1500 F. - l '; ! .4 7. Average motor winding temperature of 1800 C. '
(Class Il llotspot) . . .d.' - l l 8. Design life of 40 years. , . . . . , . i .s ! . - . .:4 - I , $4l.
. , - 4 . T.;! <h , . I ! 1 ;- 4 'l .
- B-1 . $~ y * .= . m.y vr .,7 7 m ~~..-~_ s m=,*tyeepsy v ~~- .,,s- - ~ , - w-- . r- E00 KO "CU isEH RO 13 Gdd0 tt:60 40 4T/GO - .. - -- . .. ... . ... - . - . . , . - - . - - ..
- - - - _ _ - _ - _ _ _ - _ - _ - _ - - _ _ - - _ - __ ._. _. . t ' , 0001.1D
- - f t 44 ' C* e w
, CORROSION PROTECTION t For added moisture and corrosion resistanco protection, an epoxy resin is applied to all internal motor metal surfaces - and over the varnished radiation resistant winding. This epoxy coating has been used by Reliance for over 10 years and has performed satisfactorily in special chemical ' and~ weather-proof a-c motors. It has been demonstrated that this epoxy is not affected by a lot Sodium flydroxide Solution. ,. . ,
. . , 1 . ' ~ BEARINGS AND 5EBRICATION ~ . . . . ' . ' - - - . ,, b Bearings both tlirust and radial will be of the anti-fr.i'ction
.. ! type, double shielded ball bearings. Bearings will be held V]) , in place by a cast iron cartridge enclosure. This enclosure . . provides for a large capacity grease reservoir and incorporates
~ j pJ. the "Hotermatic" lubrication system which provides an auto- ,
e e' matic grease relief along the shaft preventing overgressing. . 7/ Bearings shall have calculated B-10 Life in the magnitude of ~ J *; 100,000 hours. .: - - - . . .. . . l.] Lubrication, grease, shall be suitable for the radiation
' and te.iperature exposure. Crease will be Aeroshs11 No. 5 or. - t i Chevron BRB No. 2 In the interest of maintaining maximum bea rTg[3Jg33~~ - g lishilif.v. it it_ vacomm er.ded _that the . ,j lubricated' at two Ryggy,_ intervals _fmaxiRHEL.lD.t.975.*l).. '
d . ' .
, 4'if -
. 'k '
STANDARD FACTORY TESTS 9 . . .
- 1)
- , . ',9 Each furnished motor shall undergo standard factory test .i .
- [h
as follows: , A:.,- 1. Running light current. -
. 2. Running light watts. 4L - . . f7.j 3. Resistance, stator. 4. Hipot Test. '.f{.j S. Cold insulation.meggar. . 6. Air gap measurement. j k. .: 7. Generated noise in operation. . . e . . i B-5 .. . ' - - . I .; m.; .. - p 4.,,..,...y . . - , _ , _. ,,, ,, ,_,,, . ! Og t Pfg ? *a d ! t in(s 474*, i 4 :L.gE3 ce :e D ' A O T e C.r' - ._ _-_.__ _ - _ _ _ _ . _ _ - - _ _ - _ - _ _ _ _ - - - _ - - ._ - _ _ ._
! gj % @WhQF , ' - - LUBRICATION OF MOTORS , IOTORS furnished in all JOY Series 800/In00/2000/ Lubrication frequency per the fo.!owinn schedu' '000 fans have been lubricated with Chevron SRI #2
- s m '
0 frease and it is recommended that the customer con- HORSEPOWER CONDITIONS CoPeDITioN! ue to use this lubricaat in future lubrications. If this 1 thru 7% case cannot be obtained. the only other suggested 1800 RPM and slower 3 years 1 year [bricants are: 2 10 thru 75 PERATING TEMP. -25' C. (-15* F.) to 50' C. (120' F.) 1800 RPM and slower 2 years 6 to 12 mon; CHEVRON OIL SRI No. 2 ! 100 and greater . (6 months , SHELL OIL CO. DOLlUM R 1800 RPM and slower 1 year i TEXACO, INC. PREMlUM RB All over 1800 RPM 6 months 3 months A,INIMUM STARTING TEMP. -75' C. (-100* F.)
- STANDARD CONDITIONS: Eig
loading. clean. @ 40' C. (100, ht hours per day. actmal or i g F.) maximum ambient. SHELL OIL CO. AEROSHELL #7 .. SEVERE CONDITIONS: Twenty-four hours per day operatios shock loading. vibration. or in dirt or dust @ 40-s0* C. ( 120* F.) ambient. l sing a hand operated grease gun only, pump in the Motors with Class H, Type RN or Cl ass H, Type RH in allowing recommended grease volume: I lation systems, nuclear applications, must be lubrica with Chevron SRI #2 with no substitutions permitt
VOLUME IN CUBIC INCHES Some high horsepower motors have special bearir - FRAME SIZE 1800 RPM 3600 RPM
- "d 8 ' "'
These fans have a motor lubrication instruction pl - mounted on the outside of the fan near one of the gre 182 Thru 215 05 05 f ttings. Follow the instructions on this plate in liet - , i _ 254 Thru 286 10 10 the standard instructions printed here. 324 Thru 365 15 15 404 Thru 449 2.5 1O 143T and 145T frame motors are assembled with suffici grease in the bearing cavities to lubricate the bearing * 51 5000 2.5 1.5 , Therefore, no grease fittings are provided on these ) l." LOBRlCATION OF CONTROLLABLE PITCH MECHANISMS ' NTROLLABLE PITCH FANS require periodic lubri- O ~ ption for fan pitch contiol mechanisms and blade bear- ROLLER BEARING CONTROL MECHAN!SMS gs (depending upon hub size or style) in addition to DmCm msTRem ge fan motor bearings. An external grease fitting is pyggegs
- STANDARD
" SEVERE CoNDmoNs CoNDmoNs pated on the actuating bar of the lever assembly or on e,e casing near the actuating bar or on the mechanism P/N 500988-152, , pd bell. PUMP BY MEANS OF HAND GREASE GUN 156,157 for 26%" dia. hubs S INDICATED BELOW AT SIX (6) WEEK INTERVALS: % Cu. in. 1% cu. in.
P/N 500988-151, l BALL BEARING CONTROL MECHANISMS 164,165,166 for 17%" dia. hubs ! N ^ M LUBRICATION AMOUNT PART BERs P/N 500988-167 l P/N 500988-84, Hold the grease relief cap for 30" dia. hubs
- STANDARD CoNDITloNs: Eight hours per day. normal or lig
r 85,86,87 closed and carefully pump 3,,eing, e,,,n, g 4o C. (100* F.) maximum ambient or 26W" dia. hubs in grease until it is seen " SEVERE CONDITIONS: Twenty-four hours per day operation oozing between the bearing shock loading, vibration. or in dirt or dust @ 40-50' C. (It l housing and the adjusting 120* F.) ambient. l disc. Rotate fan rotor slow- RECOMMENDED LUBRICANT FOR CONTROLLABLE y P/N 500988-115, ly by hand while lubricating PITCH MECHANISMS: } 116,117,118 to insure grease cavity is
- for 17% dia. hubs , completely filled,
TEXACO PREMlUM RB NO. 2 E Operating Temperature (AuriONS: - 35*C (- 30 F) tO +150 C (+ 300 Grease slowly to prevent rupture of the bearing i shield. BLADE BEARINGS in textile service rotors and large Use only SRI 2 or Joy recommended equivalent horsepower units have tube fittings at the base of eac grease, blade. These should be greased once per year. _
4 , . .. HISTORY NRC CONCERN #285/8705-03 APPLICABLE CODE AND SPECIFICATION REVISIONS FOR PIPING SYSTEM DESIGN NRC CONCERN: 1. LICENSEE PLANT ENGINEERINGPNRSONNELWEREUNABLETOIDENTIFYTOTHE NRC INSPECTOR WHICH REVISION OF THE CODE WAS BEING USED BY FORT CALHOUN STATION OR, DURING PREVIOUS PERIODS OF TIME, HHICH REVISIONS WERE APPLICABLE. NRC CONCERN: 2. SINCE NEBRASKA IS A CODE STATE, LATER PIPING SHOULD HAVE BEEN T0 THE ASME B & PVC, WHEN CODE WAS EXTENDED TO PIPING. APPt.ICABLE CODES (PIPING. VESSELS) WHEN F0_R_T CALHOUN STATION DESIGN WAS STARTED - USAS B31.1 - PIPING ASME SECTION III - VESSELS - NUCLEAR VIII TANKS /H/E/VESSLES LATE 1960'S - 1967 - 1968 - USIS B31.1 - NON " NUCLEAR" PIPING USAS 831.7 - NUCLEAR PIPING CL. 1, 2, 3 ASME SECTION III - NUCLEAR VESSELS VIII - VESSELS i EARLY 1970'S - 1973 - 1974 ASME SECT. III NUCLEAR VESSELS - PUMPS - VALVES - PIPING
-. , - e . FORT CALHOUN STATION DESIGN CODES RCL PIPING: USAS B31.1 & WITH A STRESS ANALYSIS MEETING REQUIREMENTS OF ASME SECT. III - 1967 COE PIPING: USAS B31.7 1968 . OTHER PIPING: USAS B31.1 1967 _. o v . P ,..n_ A - , ' " ,,, . .n, _ .e- _
9 9 b
- D
DESIGN BASIS CODES LOCATION USAR SYSTEM (SEE RC FOR EXAMPLE) APPENDIX (SEE APP. F FOR EXAMPLE) DRAWINGS GO TO P & ID - PICK OFF IC DRAWING LOOK AT IC DRAWING - GIVES DESIGN BASIS OTHER DRAWINGS GIVE DESIGN BASIS ("D" DRAWINGS ALS0) APPLICABLE VENDOR DRAWINGS
, . . .o APPENDIX N DID NOT REDESIGN OR RECONCILE (AS REQUIRED BY SECTION XI) ANYTHING IN ORDER TO UTILIZE NEWER CODES - A NEW SET OF DESIGN BASIS CALCULATIONS (RECONCILIATI CALCULATIONS) MUST BE DONE CQE LIST EXPLAINS WHAT RECLASSIFY MEANS IN USAR APP. N , SUMMARY: RESOLUTION OF NRC CONCERN: 1. DEVELOPE PROGRAM / TRAINING SESSION TO INFORM PLANT ENGINEERING OF DESIGN 8 ASIS CODES, WHERE THEY ARE LOCATED. . RESOLUTION OF NRC CONCERN: 2. ASME SECTION XI DOES NOT REQUIRE MODIFICATIONS TO BE ACCOMPLISHED TO THE LATEST CODES. WHAT IT QQES REQUIRE IS MEETING OR EXCEEDING THE ORIGINAL DESIGN CODES. ' ,. . Y
-- r. , 05f y ,87 12:02 OFPD PM UDIES t0.003 002 e s s iMemorandum l -. . ,, , . - - - - - 1 Dam September 16, 1986 GSE-FC-86-822 l From: S. K. Gambhir J. K. Gasper ' To: W. G. Gates ! l SUBJECT: Electrical Equipment Qualification Program l Liraitorque Motor Operator Lubricants Refe'rence: GSE-FC-86-783, "Limitorque Motor Operator Qualification" The referenced letter, GSE-FC-86-783, indicated that a potential problem may l exist in the qualification of the lubricant used in the EEQ Program Limitorque l Motor Operators. This concern was amplifted in the safety System Functional Inspection Roport Nos. 50-269/86-16, 50-270/86-16, and 50-287/86-16 conducted t at Duke Power Company's Oconee Nuclear Station. The concerns are centered on two issues: - 1. The qualification of lubricants other than the lubricant used by Limitorque (Exxon Nebula EP-0, or EP-1) in the qualification testing. 2. The potential incompatibility of greases of different gelling agents (lith- ium, sodium, calcium) when mixed in the gear cases of the Limitorque opera- tors as a result of maintenance over the years. l Although the concerns had been addressed in the EEO-TER meeting response, it l was judged that the issued should be re-examined based on the infor1mation con- l tained in the TVA's and Duke Power Company's reports. Based on the infor1sation supplied in Table 1, it appears both concerns may exist at the Fort Calhoun Station. From Table 1, eight operators are known to contain Texaco Marfak Multi Purpose 2. nineteen are known to contain Exxon EP-2 and three may contain a mixture of Marfak 2 and other grease. To resolve this issue and determine a course of action, additional inforisation was obtained from Duke Power Company, a laboratory test for the gelling agent in llCV-347 was performed, and a Justification for Continued Operation was prepared, see the attached copy. The justification although technically adequate, relies on engineering judgment to support the material (grease) which was analyzed and determine the type of grease in HCV-383-3 and HCV-383-4. . . - - , , .- - - - - - --w-. -- . . . ,. -
- . -. - - -- . - . . . , . . . . , 0*i/Ne 87 12:03 OPPD BPSNDIES NO. E E a -e . . . GSE-FC-86-822 Page -2-
. , Based on the JCO, continued operation to the 1987 refueling outage is justified. GSE recommends all Marfak 2 grease be changed out to Exxon Nebula EP-0 in the 1987 refueling outage. , Please review this letter and the JC0 carefully and indicate your concurrence. If there any questions, please contact GSE. S. 1;.'Gambhir Section Manager Generating Station Engineering SKG/ $:1z ATTACHMENTS l xt: M. R. Core J. J. Foley . J. J. Fisicaro l l 0. J. Munderloh ' J. R. Tucker - EEQ File , 9 . ee S , , , , . - , - - , _ , - - , _ _ , , - - , , _ , , - - -,,,, ,,,,,m, ,m.,,-, ,.y,,, ,--,,n.,n,,,wr,,,.-,,,--.,,,,_,,,,%-.,_,..,r,,-,7,-,,-.,,,,y, , . , . , _ , , , , , , , , -
. - - - . . . - . - _._ _ . . - . . . . . . 05/14/97 12:03 OPPD BRANDIES NO.003 004 ~ - e . . ELECTRICAL EQUIPMENT QUALIFICATION LIMITORQUE MOTOR OPERATOR LUBRICANT JUSTIFICATION FOR CONTINUED OPERATION
. I. PURPotE l The purpose of this analysis is to determine if adequate justification i exists to insure (1) that Texaco Marfak Multi Purpose 2 grease and (2) a mixture of Marfak Multi Purpose 2 and the grease previously instal- led ,in three operators will not degrade resulting in the inability of the valves to perform their DBA/ Post DBA functions, (see Reference 4, 5 and 6). 4 II. MEm00 Material analysis, test results, and functional requirements will be assessed to determine o i be assessed as a group. perability. Valves with similar functions will III. INPUT DAI& 1. EEQ Manual
, 2. E0P 1, 3, 5, & 20 - l 3. USAR Section 14 4. NRC Inspection Report 50-269/86-16, 50-270/86-16, & 50-287/86-16 5. EPRI-EQAG Attachment 24 6. GSE-FC-86-783 7. Texaco Letter - C. R. Olives to Mike Watson dated 3/18/83 8. Bolt & Associated Letter - Robert O. Bolt to J. E. Thomas of Duke Power dated 6/17/86 9. Professional Service Industries, Inc., Report 174-53186-1 . 10. Rock Island Arsenal Laboratory Report 61-2132 11. Lubricant Summary Table 1 12. EEQ-EQOF Records File IV. ANALYSIS i A. The Use of Marfak 2 Grease: 1. High Pressure Safety Injection Valves HCV-314. NcV-315. and , HCV-321: These valves open on receipt of a Safety Injec- i tion Actuatinn Signal (SIAS), (s:a Reference 2 and 3), ~ f a the . I first seconds of a LOCA or M$L8, and remain open until long term core cooling is established,, if required, during the first 24 hours following a LOCA, (see Reference 2). These valves must operate in a LOCA/M5L8 as defined in Reference 1. SCEW 4-29. . e a = ---,,m--,. ,-tw,--v-q_-- we -r _.-.----,---a. - - - - - + - - . . , , . , ,v..-.an, -,-.y -sw-e.w
wwer
ww-,-< w,wwv - -wwwa,c---e-- m,- e- ---r ww------- ---*' .
____ _ _ _ _ _ _ _ _ _ _ _ . --- j - ,. ' N/14/87 12:04 CFPD E m 4 DIES NO.003 M , . . . . . . . It should be noted that the one year operating time (see Reference 1) is primarily passive and is used in the aging calculation, the 24 hours referenced previously is the active operation, based on the Large Break LOCA long term core cooling, to prevent boron precipitation. Other actions such as safety injection temination after leak isolation are not expected to stress the operator as severely as the Large Break LOCA, (see Reference 1 and 2). A review of the environmental performance data for Harfak 2 indicates that no significant degradation is expected. Refer- 7 indicates adequate thermal properties, with short time ence exposures to 350*F permissible. The gear case is expected to protect the grease and gears from significant amounts of chen- ical spray, and moisture, only the grease surface is expected to be exposed to any moisture, no degradation is expected. Pressure on the grease is not expected to affect the proper- tier of the lubricant', ' It should be noted that the grease is expected to expand thus further reducing 1.74x10}he potential for any leakage. ltadiation levels of Rads (1000 HR~ dose) are expectop. Refer- ence 7 indicates an acceptable dose ' of ' 2.3x10 Rads and Reference 8 supports the conclusion that the grease will not degrade preventing valve operation. The 1985 refueling outage inspection required by the EEQ pro- gram (References 1 and 2) indicate that the grease has not degraded. In summary, the HPSI vakres are expected to perfom their intended function with Marfak 2 grease. 2. How Pressure safety Injection Valves HCV-327 HCV-329 HCV-331, and MCV-333: These valves open on receipt of a Safety Injection Actuation Signal (SIAS) and remain open, for a LOCA/HSLB (see Reference 2). These.LpSI valves may be used to establish shutdouq cooling within the 24 hour time frame if the Reactor Coolant Systiam condition permits (see refer- ence 2). Environmental conditions are given in Reference 1- SCEW 4-34. The LPSI valves have the similar operating requirements to 'the HPSI valves discussed in IV A.1 (operating time 1000 HRS). Based on that discussion these valves should perform the intended DBA/ Post LOCA DBA function. , . e _- - -_ __-
. - . 05/14/87 13:48 CPPD BFYNDIES NO.004 002 l**
. - - . . , 3. Shutdown Cooling (SDCS) Suction Line Isolation HCV-348, (see Reference 11): This valve may be used in conjunction with the LPSI valves, (see Section IV A.2.), to establish Shutdown Cooling, (see Reference 2). The environmental conditions are given in Reference 1, SCEW 4-45. The operating requirements are to open for shutdown cooling, there is no automatic operation in a DBA. Based on that similarity (note HCV-348 is qualified for 250 HR post DBA operation vs. 1000 HR for the HPSI valves) HCV-348 can be considered operational for a 08A. 4. Shutdown Cooling Valva, HCV-347: This valve is the second SDCS suction line isolation valve, located in Room 13, see Reference 1 SCEW 4-44. The operation of this is the same as HCV-348 and is related to the 24 hour LTCC requirement. Although listed as " mixed grease," a laboratory test (see Reference g) indicates a sodium based grease which is the base of Marfak 2 (see Reference 8). Since HCV-347 in room 13 would see less severe D8A condition than HCV-348, HCV-347 is considered operational. B. H1xed Greases 1. Post Accident Containment Sump Recirculation Valves McV- 383-3 and HCV-343-4: These valves are required to open at Recirculation Actuation to provide the safety injection pumps with a suction from the containment sump. This'may occur from 20 minutes after a LOCA to several hours after a LOCA depending on break size, (see Reference 2). These valves are located in the containment extension and see a temperature and radiation stress only, (see Reference 1 SCEW 4-50, note SCEW temperature is incorrect, the value is 174*F). The type of grease in HCV-383-3 and HCV-383-4 at.the time of mixing is judged to be Marfak 2. This judgment is based on visual examination of samples of grease taken during the 1983 refueling outage, and a recent laboratory test (Reference 9) of grease samples taken from HCV-347. The grease samples taken in 1983 were very dark in color with the same appear-
ance as Marfak 2 2 Laboratory tests on the HCV-347 lubricant I which contained both " original" and Harfak 2-indicated virtu- l ally identical ' concentrations of the bottom of the grease. gelling agent (sodium) at the top and Based on the similar appearance and laboratory analysis, the lubricant is believed to be Harfak 2. i l l l
I i . . J - , +- .,-.,-,-w ,-,--,-.,r--r, ,-_w-,,----,--,.,,--,-n-., .n, ,-.,--. ,,,,,-n,,,,r.-,_. . , - - , . , , - . - - - ,-,,.-..,.--,--,.-r,,---- ,---n, -
. . . . . . -- . - ~ _ - . . ~ _ - - . . - ~ _ - .= . ..- - . .-. - . '
. . .- ' 05/14/87 13:48 CPPD BRAND!ES NO.004 003 - - 4**e ' = e ,. All Limitorque valve operators appear to have had their lubri- cant change out at some point in time as evidenced by the samples. No maintenance records of this were found. It is known that Limitorque originally supplied the operators with I ' a Exxon Nebula EP calcium based lubricant which is tan in color. . It should be noted that industry records indicate that Limitorque supplied certain non-containment operators with a Sun 011 grease which is. lithium based, which also sup- ports the change out judgment. Based on the above discussion it appears. that no mixing occur- red and the Marfak 2 can be considered adequate. If for.what- - ever reason either of the original treases remains in the operators. Reference 8 indicates adequate compatibility with either the Exxon or Sun 011 products. Given these condi- tions, the valves should operate satisfactorily. , . . t ATTACHNENT 1. NRC Inspection Report 50-26g/86-16, 50-270/86-16,.&.50-287/86-16. 2. EPRI-EQAG Attachment 24 i > 3. GSE-FC-86-783 4. Texaco Letter
5. Solt & Associated Letter ' 6. Professional Service Industries, Inc., Report 174-53186-1 ' i 7. Rock Island Arsenal Laboratory Report 61-2132 t 8. Lubricant Summary Table I . 4 9 . e l . l . - - - }}