ML20215D027
| ML20215D027 | |
| Person / Time | |
|---|---|
| Site: | Braidwood  |
| Issue date: | 07/07/1986 |
| From: | Nagy E, Stroh D COMMONWEALTH EDISON CO. |
| To: | |
| Shared Package | |
| ML20215D019 | List: |
| References | |
| 2314U, BWPT-RY-17, BWPT-RY-17-R, BWPT-RY-17-R0, NUDOCS 8610100584 | |
| Download: ML20215D027 (22) | |
Text
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- a. Test Evaluation
-+ R:: vision 0 i 12.0 TEST EVALUATION 12.1 Acceptance Criteria Evaluation 12.1.1 Acceptance Critaria 4.1:
The Pressurize;- Pressure Control System shall demonstrate that.it can maintain a ! 30 psi Pressurizar Pressure span in AUTO (Steps 9.2.lc, 9.2.8, 9.2.13, 9.2.14b, 9.2.20 and 9.2.25). At the indicated steps, the pressurizer control system maintained a pressurizer pressure of i 30 psi when in AUTO. Acceptance Criteria 4.1 was met.
12.1.2 Acceptance Criteria 4.2:
The following Pressurizer Pressure Alarms, Trips and Setpoints (Section 9.3) shall function:
PZR PRESS HIGH RX TRIP SETPOINT ALERT (2360 -
2410 psig) (Step 9.3.11)
PORY 1RY456 OPENS (2310-2360 psig) (Step 9.3.10)
PORV 1RY456 CLOSES (2290-2340 psig) Step 9.3.16)
P%R PRESS HIGH (2285-2335 psig) (Step 9.3.9)
PZR PRESS LOW RX TRIP STPT. ALERT (1860-1910 psig) (Step 9.3.23)
PZR Pressure Low SI/RX Trip (1804-1854 psig)
(Step 9.3.25). At the indicated steps, all pressure alarms, trips, and setpoints functioned
, properly. Acceptance Criteria 4.2 was met.
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ADOCK 05000456 FDR ,
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BwPT-RY-17 T8st Evaluation Rsvision 0 e 12.1.3 Acceptance Criteria 4.3:
The Proportional - Integrating - Derivative 1
(PID) controlled functions shall occur in the following order while increasing Pressurizer r Pressure:
Heater Group C Minimum Output (2250 psig nominal) (Step 9.3.5) l Pressurizer Spray Initiated (2260 psig nominal)
(Step 9.3.6)
Pressurizer Spray Valves PJLL OPEN (2310 psig i
nominal) (Step 9.3.7b)
"PZR PRESS CONT DEV HIGH" alarm (2310 psig nominal) (Step 9.3.8)
PORV 1RY455A OPENS (2335 psig nominal) (Step 9.3.10). At the indicated steps, all controlled functions operated properly on increasing pressurizer pressure. Acceptance Criteria 4.3 was met.
12.1.4 Acceptance Criteria 4.4:
The Proportional - Integrating - Derivative i
(PID) controlled functions shall occur in he I
following order while decreasing Pressurizer Pressure:
- PORV 1RY455A CLOSES (2315 psig nominal)
(Step 9.3.16) i i
Group C Ramping ON (2250 psig nominal) (Step 1
9.3.18a) i b
l 2 I
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Test Evaluation R: vision 0 3 Group C Full ON (2220 psig nominal) (Step t
. 9.3.18b)
I'
- PZR PRESS CONT DEV LOW HEATERS ON alarm with Backup Groups A, B and D Energizing (2210 psig nominal) (Step 9.3.19a). At the indicated steps, all controlled functions operated properly on decreasing pressurizer pressure.
Acceptance Criteria 4.4 was met.
12.1.5 Acceptance Criteria 4.5:
The following Pressurizer Level Alarms, Trips
- and Setpoints (Section 9.4) shall function
- PZR LEVEL HIGH RX TRIP STPT ALERT (89-95%) (Step 9.4.9)
PZR LEVEL HIGH (67-73%) (Step 9.4.7)
- PZR LEVEL CONT DEV HIGH HTRS ON (Leef + (2-8%)]
(Step 9.4.16)
PZR LVL LOW HTRS OFF LTDWN SECURED (14-20%)
(Step 9.4.17). At the indicated steps, all level alarms, trips and setpoints functioned i properly. Acceptance Criteria 4.5 was met.
12.1.6 Acceptance Criteria 4.6:
j Each Pressurizer Power Operated Relief Valve (PORV) shall have an opening response time of 2.0 seconds maximum (Steps 9.5.14, 9.5.27).
Opening response time of 1RY456 PORV was l
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Tsat Evaluation Rsvision 0 4
verified less than 2.0 seconds at steps 9.5.14.
PORV 1RY455A at step 9.5.27 did not meet the acceptance criteria. Its stroke time = 2.3 seconds. Deficiency RY-17-310 is tracking this
- resolution.
12.2 Test Section Analysis
- 12.2.0 Sections 3 through 8 i
Section 3.0: Test Objectives.
This section lists the test objectives for l ,
BwPT-RY-17. No TCR's or deficiencies were i
written for this section. All test objectives were met.
Section 4.0: Acceptance Criteria TCR #1 was written at criteria 4.5 to change the expected range for "PZR LEVEL HIGH". This was to incorporate PED's comments needed for approval of BwPT-RYOl7 Rev.'l.
Section 5.0: References TCR #1 was written for many steps in section 5.0 in order to update the print revisions. No deficiencies were written for this section.
Section 6.0: Prerequisites TCR #1 was written at step 6.3 in order to
^
] update the calibration dates on several instruments. NO deficiencies were written for this test section.
Section 7.0: System Initial Conditions 4
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No TCR 's or dsficiencies were written for this test section. The strip chart recorder in step t0 5,,/ 7.3.1 has "N/A" entered for cal date and due date because the recorder is calibration checked each time it is used. This was done with a signal generator (7.3.3) and is shown on the strip charts attached in Section 14.0.
Section 8.0: Precautions TCR #1 effected this test section at steps 8.5 and 8.10. TCR #1 was written to. incorporate PED's conditional approval comments. No deficiencies were written for section 8.0.
12.2.1 Section 9.1: Preliminary Adjustment of Pressurizer Continuous Spray Flow Valves (IRY8050 and 1RY8051). TCR #1 was written at the " NOTE" after step 9.1.6 to correct and clarify the statement. No other TCR's or deficiencies were written for section 9.1. The test results of section 9.1 are acceptable.
12.2.2 Section 9.2: Pressurizer Pressure Control System TCR #1 was written for steps 9.2.10 in order to correct a step reference. No other TCR's or deficiencies were written for this test section. The test results of section 9.2 are acceptable.
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@iPT-RY-17' Test Evaluation Rsvision 0 4 12.2.3 Section 9.3: Pressurizer Pressure Control, Alarm, and Setpoint Verification. This test J
section is performed in two discrete parts. The first, uses the PZR Heaters to increase RCS pressure while documenting the various control, I
alarm and setpoints. The second uses one of the two PZR Spray Valves to depressurize the RCS while again, documenting the various control, alarm and setpoints.
Prior to energization of-the pressurizer heaters, initial pressure readings were taken.
As is shown on Data Sheet 11.3, pressure loops 455 & 456 were approximately 10 to 20 psig lower
- than pressure loops 457 & 458. This 4
() relationship held true throughout the test section when data was recorded simultaneously from the four narrow range RCS pressure loops (P455-458). Post test calibration of these transmitters showed a negative .20 to .30 ma error in the 25% to 100% range. The out of i
j tolerance calibration of these transmitters had no impact on the test.results based on the following. When verifying setpoints and alarms which were not part of the Master Pressure Controller, IPC455A, data from all fc.or narrow range pressure loops were recorded, therefore, P-455 & 456 need not be used. When setpoint and O
6
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"BwPT-RY-17 ^
Test Evaluation Ravicion 0 2-control functions were verified with the Master Pressure Controller, P-455/456 was selected as the input to the controller. All setpoint/ control functions were then read off P-455/456 indicators. Therefore, the error to the control was also reflected in indication (i.e. they are both offset by the same error).
During the increase in RCS Pressure, the following control functions / alarms were verified (VIA IPC-455A):
l Control Heaters OFF, nominal 2250, actual 2268 Spray Valves begin opening, nominal 2260, actual 2275 Spray Valves full open, nominal 2310, actual 2275 Control Deviation Alarm, nominal 2310, actual 2275 PORV 455A OPEN, nominal 2335, actual 2295 The alarms /setpoints which were not controlled i
l via the Pressure Master Controller were also j
verified:
t PZR Press HIGH, nominal 2310, actual 2310 l
PORV 456 OPEN, nominal 2335, actual 2335 )
l Rx Trip Setpoint Alert, nominal 2385, actual 2375, 2390 & 2400 (for P455, 456, 457, 458 respectively).
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- i As can be seen from this data, the setpoints and )
alarms which were not associated with the
- }
O Pressurizer Master Controller were acceptable.
However, the data associated with the Master Controller appears questionable. The following
, discussion will show that the centroller operated properly and that the data is acceptable.
NOTE: References to Attachments A, B, and C can be found in Section 14.0 of the test.
Attachment A - Pressurizer Pressure Recorder PR455 Attachment B - NCB Card P&I Dinamic Response Measurement f) i Attachment C - IPK-455A Pressurizer Master controller Auto Manual Station Indicator s J
As mentioned earlier, the Pressurizer Backup Heaters were used to increase RCS pressure.
1 Control Heaters OFF and the initiation of ]
Pressurizer Spray were the first control points verified. These two points were higher than the I
nominal values. Normally, a P&I Controller j (Proportional & Integral ) will " anticipate" a transient. Therefore, one would expect these l
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- values to be less than nominal (i.e. < 2250 &
, 2260 psig respectively). Attachment B shows the b(./ input / output relationship for the Westinghouse P&I Controller (NCB Card). For a given input (i.e. process not at setpoint) the output will be a signal proportional to the input (error multiplied by the gain) plus the same factor (Error x Gain) times a second variable the
" Reset". The Roset is the time in seconds it
- takes the Integral portion of the output to reach a value equal the Error times Gain value.
This value will be less than one if the error signal has been present for less than the reset value. Appendix B shows this graphically. It should be noted that Appendix B is for'a step change, steady state condition. Normally, the process would be changing (hopefully, being corrected back toward setpoint) thereby changing the gain times error value. For the Master Pressure Controller, IPC-455A, the gain is 5 psi / psi and the Reset is 900 seconds.
Attachment A is a recording of the RCS pressure during Section 9.3 (From Recorder IPR-455). The chart is broken down into eight regions by division lines one through seven. Prior to "ONE" the RCS was being held stable at approximately 2240 psig using the Backup Heater 9
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BwPT-RY-17 T4st Evaluation Rsvision 0 in " MANUAL ON" and the remainder of the Pressurizer Pressure Controls in Auto.
The
.O s-) - Spray Valves were modulated open approximately 20 to 30% (The shift on duty chose to operate in this manner which is a conunon practice among shifts). When initial conditions for Section 9.3 were being established, the Heaters were placed in " AUTO". This caused the downswing in RCS pressure at "ONE". (Due to sprays being open.) The Spray Valves modulated closed and the proportional heater began to Ramp On as a,
pressure decreased below the setpoint. (See l
Attachment C for a graphic look of controller output as a function of percent output. The control functions always operate at the listed percent output independent of the RCS Pressure.) Pressure began to turn upward near "TWO", but the integral portion of the controller continued decreasing the output of the controller and at "TWO", the Backup Heaters came on. The rapid increase in RCS pressure reset (shut off) the Backup Heaters near "TWO".
Between "TWO" and "THREE", two additional step i
changes are indicated. The first was caused by selection of different channels on the recorder l (per step 9.3.lc). The second by placing the recorder to channel 455 as noted on the trace.
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- At "THREE" the Pressurizer Backup Heaters were energized manually per step 9.3.3. It is i
N- '
important to note at this time that although RCS Pressure was at approximately 2235 psig, that it had been below the setpoint of the controller for nearly an hour. This meant that the output of the controller was less than the nominal value (see Attachment C). This is due to the integral portion of the controller which was integrating in the negative direction during this period of time. At the same time the controller output was causing the RCS pressure to increase towards setpoint (the output of the controller would be somewhere between 10 and
() 15%). At equilibrium and the RCS at the setpoint pressure, the controller output would be at 25%. On a proportional basis, each 10% of controller output is 16 psig. Therefore, the controller output was 16 to 24 psig behind the i
actual RCS pressure. Now, when the heaters were manually energized per the test, the feedback (positive error) had to overcome the negative going signal of the integrater . The net effect was the apparent " lag" vs. the expected
" anticipation" for the Control Heaters Off and Spray Valves Open signals. Had the 455 Auto / Manual Station been toggeled from Auto to Manual to Auto just prior to energizing the 11 2314u
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- pressurizer heaters, the integral portion of the circuit would have been reset. Under these
(' _,,7 conditions, the expected values for Heaters Off and Sprays Open would have been exceeded. A prerequisite should be added to ensure the RCS pressure is at 2235 psig, in " Auto" for one hour prior to manually energizing the Pressurizer Heaters or the Auto / Manual buttons toggeled.
The next apparent problem was caused by test methodology. After the Spray Valves were verified to start opening, the test calls for the Spray Line Manual Block valves (lRYO22 & 24) to be closed. The desired effect is to allow the increasing pressure transient to continue.
Unfortunately, one of the block valves was inaccessible. The alternate valve (lRYO23) was difficult to close. It required a " breaker bar" and the additional aid of a second B-Man. It took approximately one-half hour to close the Spray Line Isolation Valves. This can be seen on Attachment A between lines "four" and "five". The net result was the controller output (at about 50%) maintaining the Spray Valves open about 20 to 30%, thereby 1
depressurizing the RQS toward setpoint. The output remained steady as the decreasing error signal was canceled by the increased output by O
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- the integrater . When the Spray Line Block i Valves were finally closed, RCS pressure had
~
decreased to approximately 2240 psig while the 1
controller output was still at 50%. When the RCS pressure again began to increase (lines 5 to 6 on Attachment A), the controller output needed-only to increase 22% (50% to 72%) to modulate 4
the Spray Valves the remainder of the way open.
Twenty-two percent controller output is approximately equivalent to 35 psig. From where the RCS pressure started from (2240 psig) and by adding the required 22% controller output (35 i
psig) the RCS pressure at which the Spray Valves will be 100% open will predict the full open value (2275 psig). Following the same lines of
(
reasoning, it can be shown that the remaining controller output functions operated where they y should have. The next point was the " Control 3
Dev. Alarm". This alarm trips at the same j controller output as " Sprays Full Open" (72%).
, Therefore, the recorded value of 2275 for this j control function is satisfactory. The last l control function from the output of the Master Controller is "OPEN PORV 455A". This output actuates at 87.5% which is 37.5% or 60 psig from i.
where the increase in controller output began.
Adding 60 to 2240 psig results in 2300 psig.
i ,
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6tinf-RY- M Test Evaluation Ravision 0
- The undershoot of the setpoint by 5 psig is attributed to the additional five minutes the integrator was adding to the output.
The remainder of the setpoints/ alarms on the increasing signal were from the proportional only portion of the circuitry. These values are acceptable.
As previously described, the decrease in RCS
. pressure was achieved by opening one of the PZR Spray Valves. This transient can be seen on Attachment A between 6 & 7. With the output of the Master Controller pegged at 100% and above the setpoint for about forty minutes, there would be some delay before the output would decrease with the decreasing RCS pressure. The order in which the control functions reset with decreasing RCS pressure was acceptable. The alarms and setpoints which were verified independent of the output of the Master Controller were also acceptable.
- Additional consnents for Section 9.3 are as
, follows:
TCR #1 was written at steps 9.3.lc, 9.3.5, i
i 9.3.18a, 9.3.22 to incorporate PED conditional approval comments. TCR #4 was written at steps 9.3.7a and 9.3.14a to close valve IRYO23 instead of valve IRYO22 (Loop 4 Spray Line Manual 14 2314u
ui31nRWRG1 Tact Evaluation Rsvision 0 Isolation Valve). Valve IRYO22 was inoperable due to scaffolding interfering with valve movement .
TCR #5 was written at step 9.3.14a to avoid unisolating a pressurizer spray valve while it was 100% open.
TCR #2 was written at step 9.3.32 on data sheet 11.3 to add an expected range. Deficiency "G" was written at step 9.3.17 to identify an apparent problem with annunciator 06D02. The STE reverified proper operation of the bistable and closed Deficiency "G". TCR #6 was written to add test step 9.3.31a. This new step allows the STE to release the pressurizer pressure safety injection reset block switches at the main control board because the SSPS mode selector is in " test" as per step 7.4.2.
Deficiency "H" was written at step 9.3.32 because the pressurizer heaters did not de-energize after properly executing the test step. Upon investigation, the STE found that the heaters sh'uld o not de-energize given the operating conditions at the time of test.
Deficiency "H" was closed.
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, Although tha initial portion of this test section did not perform as intended, the
() operation of the Pressurizer Master Pressure Controller was proper for the conditions under '
which it was tested. The other alarms and setpoints verified in this section were acceptable. Therefore, the test results of section 9.3 are acceptable.
12.2.4 Section 9.4: Pressurizer Level Indication and Level Control. TCR #1 was written at steps 9.4.lc, and 9.4.7 and 9.4.23 in order to incorporate PED's conditional approval :
consents. TCR #7 was written at steps 9.4.8 and 9.4.23 in order to set up the conditions required to generate P-10 permissive.
Deficiency 'I' was generated at steps 9.4.14 and 9.4.22 because the stabilized pressurizer level was outside the expected range. Deficiency 'I' was processed as RY-10-309 and is open at this time. Deficiency 'J' was written at step 9.4.17 because ICV 459 letdown isolation valve did not close when " LETDOWN SECURED" alarm annunciated as per test step. Upon investigation, valve ICV 460 letdown isolation was found to have closed on a signal from the 460 loop. Further level reduction could not be done because ICV 460 was closed. In order to test the CV459 valve
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BwPT-RY-17 Tsot Evaluntion R:visien 0
- and clear deficiency 'J', channel selector was put to "CH 459/461" which allowed the 461 loop to control 1CV459 valve, and steps 9.4.17 through 9.4.23 were reperformed and verified.
Deficiency 'J' was closed. TCR #8 was written at step 9.4.lc on data sheet 11.4 to correct the units of an expected value. No other TCR's or deficiencies were written on section 9.4 and the
/ test results are acceptable.
12.2.5 Section 9.5: Pressurizer Power Relief Valve Response Time. TCR #3 was written at step 9.5.lc to put LK-459 in manual control because it had not been fine tuned as per section 9.4 because section 9.4 had not been completed. TCR
- 3 did not effect test results. TCR #9 incorporated new test steps 9.5.12a,b,c, 9.5.14a, 9.5.25a,b,c, 9.5.27a. This was needed to incorporate interlock testing, as per FSAR 14.2-50. TCR #1 was written at steps 9.5.11, 9.5.21, to incorporate PED's conditional approval comments. Deficiency 'A' was written at step 9.5.27 to identify a valve stroke time above the maximum allowed. Instrument air to the valve was changed, the steps reperformed and verified, and deficiency 'A' was closed .
Deficiency 'B' was written at steps 9.5.12 and 9.5.25 to identify an annunciator which did not 17
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BwPT-RY-17 6.
T:st Evaluation Ravision 0 alarm. Upon investigation, it was found that the setpoint of 160*F was never reached. After O- pressurizer pressure dropped 100 psid, the PORVS i
I were closed (as per the test step), however the !
short open time did not allow the piping i
temperature to rise above 130*F. Therefore, the high temperature alarm never annunciated. Steps 9.5.11 through 9.5.13 were reperformed on 4/9/86. This was done to retest the PORV per TCt #9. At this time, the valve was opened long !
enough to heat the discharge piping above 160*F. Annunciator 06C06 actuated per step 9.5.12 and the temperature documented (165'F).
Deficiency B was closed. Post test TRB comments required a TCR be added to allow skipping the i
annunciator alarm the first time through (on 3/29/86). This was done as a late entry on 5/23/86. At step 9.5.15, a deficiency should have been generated because the recorded data was outside of the expected range, but was not.
This deficient condition was identified after the test was completed and identified as RY-10-313. Because the RTD's for the safety 4
valve discharges are so close to the downstream piping for the leaking porvs, it was actually recording PORV temperature. Temperature measurements at the safety valves indicated that 18 I l
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cutnsmo ev
. Tcat Evaluation
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-~
and the safety valves do not leak by. After the
% RTD's are moved closer to the safety valves, Deficiency RY-10-313 will be closed. Deficiency
'E' was written at steps 9.5.16 and 9.5.18 to identify an apparent valve leak through on PORY 1RY-456. The deficiency is still open as RY-10-315 and is assigned to PED and PCD for closing. Deficiency 'D' was written at step 9.5.14 to identify an improper valve stroke time. However, the close stroke time was identified whereas the opening time has the acceptance criteria. The opening time did meet the acceptance criteria and deficiency "D' was closed. Deficiency 'C' was written at step 9.5.31 to identify an apparent valve leak through on PORV 1RY-455A. The deficiency is still open as RY-10-309 and is assigned to PED for closing. Deficier.cy 'F' was written at step 9.5.13a because PORV 456 did not auto close.
1 After replacing a bad bistable, step 9.5.13a was 1 reperformed and verified. Deficiency 'F' was closed. There were no other TCR's or deficiencies written for section 9.5 and the results are acceptable.
12.3 Additional Recommended Testing NONE O
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.i' 12.4 Recommendations Upon review of the test and test data, it is my recommendation as the STE, that this system be accepted for turnover from Project Start-up to the Station Operating Department.
! .I p % p & ,>. s u e Dan Stroh
- System Test Engineet iA ~
7~ 7- E O Ge Q gy Test Director
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