ML20234C233
| ML20234C233 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 09/01/1987 |
| From: | SACRAMENTO MUNICIPAL UTILITY DISTRICT |
| To: | |
| Shared Package | |
| ML20234C212 | List: |
| References | |
| IEB-85-003, IEB-85-3, PROC-870901, NUDOCS 8709210210 | |
| Download: ML20234C233 (34) | |
Text
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SACRAMENTO MUNICIPAL UTILITIES DISTRICT l
RANCHO SECO NUCLEAR GENERATING STATION, UNIT #1
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MOTOR-OPERATED VALVES PROGRAM i
I SEPTEMBER 1, 1987 1
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TABLE OF CONTENTS TITLE PAGE INTRODUCTION-AND BACKGROUND 1
IE Bulletin 85 -l District Submittals MOV Refurbishment Project Formation WORK PROCESS 4
Project-Management j
Engineering Maintenance I
Testing Quality Documentation of Quality Concerns PROGRAM PRODUCTS 14 Differential Pressure Determination Calculation Procedures Special Calculations Documentation of MOV Data Training 1
l CONTINUATION OF PROGRAM FEATURES 18 IEB 85-03 FINAL REPORT PLAN 19 SCHEDULE ~
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REFERENCES 24 FIGURES 1 THROUGH 7 FOLLOW PAGE 25 3904D/2 i
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INTRODUCTION AND BACKGROUND i
IE Bulletin No. 85-03 The Nuclear Regulatory Commission (NRC), recognizing that the performance of motor-operated valves (H0Vs) is an industry-wide concern, initiated several actions to improve the data available for decision-making.
Among these actions, the Office of Inspection and Enforcement (IE) issued IE Bulletin No. 85-03 (IEB 85-03).
See Reference 1 for the full title of IED B5-03.
l IEB 85-03 requested licensees to develop and implement a program to ensure that switch settings on certain safety-related MOVs are selected, set,'and maintained correctly to accommodate the maximum differential pressures a
expected'on these valves during both normal and abnormal events within the design basis.
i IEB 85-03 describes the program for high pressure coolant injection MOVs and emergency feedwater MOVs, summarized as follows:
document the' design basis for the operation of each valve, including a.
maximum differential pressure, b.
establish correct switch settings, c.
test for operability at maximum dif ferential pressure, d.
by procedure, ensure that switch settings are maintained, e.
by May 14,1986, report the results of Item a and report the program to accomplish Items b through d., including a schedule for completion (latest date for completion, November 15,1987), and f.
report on completion of the program (latest date for report, January 14, 1988).
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't District Submittals i
'i SHVD letter, Ref. 2, provides the retort required by Item e of IEB 85-03.
j This letter presents the documentation of the design basis for the operation j
of each identified valve; outlines the program to address IEB 85-03 Action Items b, c,.d, and f; and includes the schedule for completing these items.
i SMUD letter, Ref. 3, expanded the scope of the M0V Refurbishment Program to include:.(1) all safety-re:ated MOVs, and (2) all other MOVs on site.
This' letter.also introduced the use of MOVATS, Inc., response signature analysis
-l equipment to enhance' the prcgram.
Additionally, this letter committed the District to complete the work on thirty IEB 85-03 MOVs and all other j
safety-related MOVs prior to restart. The structure and format of the Ref. 3 letter includes,'. for each element of the program, the '" Current Program in Progress" description which outlines the enhancements which result in a more comprehensive program.
Although not specifically stated, the " Current Program in Progress" was intended to supersede the program described in the Ref. 2 letter.
As a result of the ' program that was developed in response to IEB 85-03, problems with the MOVs were identified in Licensee Event Report (LER) 87-06 (Ref. 4).-
LER 87-06 has been updated regularly as new information becomes available. The LER states the intention to implement an MOV configuration i
control program, as well as preventive and corrective maintenance programs, j
prior to restart.
SMUD letter, Ref. 5 states that the District has expanded the MOV refurbishment program beyond the original scope described in previous submittals.
Ref. 5 also confirms that the expanded program does not reduce I
any of the District's original commitments to IE Bulletin 85-03.
All safety-related MOVs will still be completed prior to restart f rom the
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current outage.
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'MOV Refurbishment.
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Initial efforts to comply with IEB 85-03 involved primarily maintenance activities.
Maintenance Inspection Data Reports (MIDRs) were completed to 1
document the "as found" condition of the thirty MOVs affected'by IEB 85-03.
The MIDRs_ contain, among other information, torque switch settings, limit switch settings, mechanical condition,' electrical condition, and lubricant condition'. Operator thrust and torque. values were calculated and torque switch settings determined, for comparison with existing settings.
Samples of lubricants were gathered for analysis.
As the-? refurbishment of operators progressed, it became apparent that a more detailed and comprehensive plan was needed'.
Proiect Formation i
In. order to ensure timely completion of the MOV program, a "special project" I
was organized under a Project Manager.
Peonle and funding were provided by functional managers such as engineering, maintenance, and operations, with direction, coordination, and allocation of resources performed by the project organization.
See Figures 1, 2, and 3 for organization charts.
The project organization concept was selected for its ability to expedite production, and improve quality, mainly by allocating resources to critical path activities.
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WORK PROCESS
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Project Management The District's May 16,1986 (Ref. 2) and November 5,1986-.(Ref. 3) a submittals ' described and summarized the District's MOV refurbishment plan to comply with IEB 85-03'.
To meet the varied requirements and expanded l
1 commitments of the Rancho Seco Motor-0perated Yalve Program a job-specific project team was organized.
The centralization of l
responsibility in an M0V project team provides the rapid response, decision-making, and reporting necessary for a critical work scope such as MOV refurbishment, engineering, and testing.
The MOV Project was le'd by a Project Manager.
The Project Manager and his assistants provided the interface to plant management for all matters concerning MOVs. They also established priorities for the Project's component groups such as engineering, maintenance, procurement'and testing. The management of each of these departments was responsible for accomplishment of the assigned tasks.
The Project's work process was established by the Project Manager is shown.in Figure 4 This process required efficient interfacing between maintenance, engineering and M0 VATS testing. The Project Manager's overview position allowed rapid interjection when the work process appeared unable to handle a particular situation.
The Project Manager reported daily in summary fashion to the Manager, Scheduling and Gutage Mcnagement. This report gave the number of MOVs completed and the status of any particular problem area.
Each week a more formal meeting provided each department within the MOV Project an opportunity to report on status and problems.
This meeting was run by the Project Manager for the benefit of the Manager, Scheduling and Outage Management and his staff.
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A working' level coordination meeting was held daily to provide effective communication between engineering, maintenance, planning and procurement. All activities were planned using the Project /2 system and were coordinated with the overall restart schedule.
The project work process has become smooth and the Project Manager is no longer resolving programmatic concerns. Therefore, NOV mainte' nance and l
. refurbishment is now being accomplished by the normal plant method of performing maintenance.
Engineering 4
Input data for the engineering calculations to determine the required thrust for M0 VATS verification is obtained from four sources:
1.
A walkdown is performed.on each MOV to obtain nameplate data for the valve, the operator, and the operator motor. Additionally, the stem l
s diameter at the packing gland and the operator is obtained along with the stem thread pitch and lead information.
2.
The valve manufacturer is contacted and the valve seat port diameter or area and the maximum allowable thrust or torque which the valve i
can withstand is obtained.along with identification of the limiting I
component.
3.
Limitorque publication SEL-9 is used to establish the maximum standard thrust or torque rating for the motor operator. This data is supplemented by a Limitorque letter to SMUD allowing normal opert. ting thrust ratings to be extended to 110% of the published values during coast down (post-motor cutoff) portions of the valve operation.
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Each valve is reviewed by the cognizant' system engineer and the maximum I
differential pressure and system pressure conditions for valve operation from open-to-closed and from closed-to-open is determined and documented.
-The input data obtained through the above four channels is tabulated on a permanent reference document identified as.the E-1012 drawing.
A unique drawing is prepared for each MOV assembly.
l A calculation is then performed for each valve assembly, to determine the l
required thrust / torque to' stroke the valve agninst the defined maximum system pressure conditions.
This calculation is based on the Limitorque operator sizing criteria as outlined in Limitorque publications SEL-1 i
through SEL-12.
This calculation establishes the' adequacy of the valve and operator assembly to produce the required thrust without exceeding the valve or operator capabilities.
J If the calculation establishes the need to replace the operator, the operator gearing, the motor, the spring pack, valve internal components, or valve assembly, Nuclear Engineering provides the resolution and documents the required changes.
A Work Request (WR) is generated which directs the craf t to perform the desired work.
Prior to runnir.g the M0 VATS test, the operator, including the motor, is i
refurbished (disassembled, inspected, replacement parts obtained as required, reassembled) to return the unit to as close to "new" condition as possible.
The valve assembly is refurbished if necessary to resolve a known maintenance problem (e.g., internal process leakage, stem packing leakage, etc.)
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The M0 VATS test is then performed to confirm that the desired threst can be achieved without exceeding the valve, operator, or motor allowables.
If the MOVATS test data establishes the need to replace the operator, the operator gearing, the motor, the spring pack, or the valve internal components or the valve assembly, Nuclear Engineering provides the resolution and documents the required changes.
A Work Request (WR) is generated which directs the craf t to perform the desired work.
After rework has been completed, the assembly is retested using the MOVATS equipment to verify proper operation and to verify that required thrust values are achieved.
Maintenance The Maintenance Department Program was developed with the intent of complete motor operator and valve refurbishment.
A mechanical crew was established to test spring packs, inspect internal components, lubricate operators, and repack valves.
An electrical crew was set up to test and refurbish motors, perform internal inspection, modify environmentally qualified wiring, l
replace parts, and perform the motor operator analytic testing.
Under the Maintenance Manager, these functions were directed by the Maintenance Superintendents (Mechanical and Electrical) and the Preventive Maintenance Supervisors.
Training was conducted with spare operators and approved procedures for refurbishment. Training classes were set up on M0 VATS equipment.
Both classroom and in-the-field training was completed by MOVATS field representatives and Power Safety International personnel.
Initial refurbishment of the motor operator included:
l Vibration analysis testing of the motor to determine whether bearing o
replacement was required o
Visual inspection of the motor to determine the condition of the motor grease seals.
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. Inspection, refurbishment or replacement of motor, torque switch, limit switch o
Replacement of internal wiring (EQ requirement) o-Replacement of 0-rings and seals (EQ requirement)
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o Install vent valve if necessary (EQ requirement) o Correction of problems discovered during disassembly o.
Removal of the spring pack for testing o
Inspection of alignment o
Inspection of all internal parts o
Repack the valve o
Refurbish the valve if necessary o
Lubricate operator I
o Determinate electrical connections Following the refurbishment, the valve was ready for testing, using equi.pment f rom M0 VATS, Inc. (Motor-0perated Valve Analysis and Testing System).
The M0 VATS test was used to:
o Record signature traces.
o Set torque switches.
o Fine tune limit switches for open and close limits.
o Set torque switch bypass limit switch to ensure that it covers unseating of the valve o
Record information and transfer to disk storage for trend analysis.
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o Perform " Motor Load Transducer" (MLT) Test.
If valve packing is adjusted later, the MLT will be performed again to ensure thrust threshold valves have not been exceeded.
Several improvements were required to perform these maintenance activities satisfactorily.
Procedures were rewritten to:
o Make them workable.
o Meet quality standards.
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o Ensure purchase of Class 1E parts, where required. -
o Minimize work delays due to unforeseen problems.
1 Training on'the' revised procedures was. improved to meet high quality i
s tanda rds'.
To ensure continued proper performance of MOVs, a preventive maintenance program is dlanned which' includes the following:
o Categorize -all MOVs in accordance with Maintenance Administrative Procedure MAP-0009.
o Category 1 MOVs are those valves requiring surveillance by Section XI of the ASME Code, as determined by Engineering, o
Category 2 MOVs are all other motor-operated valves.
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Review the history and set schedule for tasks. Schedule will cover one refueling cycle.
o Every refueling cycle, all MOVs will be lubricated, opened, and inspected.
o If a problem has been.noted, or if corrective' maintenance has been done, M0 VATS testing will be performed as Post-Maintenance Testing (PMT).
o Every refueling cycle, all Category 1 MOVs will be tested and analyzed for trends.
l See Figures 5 and 6 for illustration of the planned Preventive Maintenance program.
Testina The Nuclear Engineering Department determines the various parameters of the M0V.
These parameters include:
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Target thrust band (open) o Target thrust band (close) 39040 9
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o- ' Torque switch bypass protection margin (open) o Torque switch bypass protection margin (close) q o
Desired valve travel o
. Desired valve timing o-Open and close light indication i
Using M0 VATS equipment, electrical maintenance personnel set up the MOV to the parameters-specified by Engineering.
The M0 VATS system allows the electricians to monitor spring pack movement, stem thrust in the open direction, torque switch trip points, and all limit switch trip points.
The spring pack movement is then calibrated to the thrust on the load cell in the open direction.
From this calibration, the valve thrust into the seat can be determined.
Also, a motor load ' signature is taken, which can be used in the MOV trending program.
The data gathered from the test is stored on bubble memory and reviewed by trained personnel'.
i The test data is transferred from bubble memory to a floppy disk for
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permanent storage and future reference.
The signatures are then analyzed to ensure that the engineering parameters are met.
Also, the analyst looks for possible MOV degradations, which could include:
o Loose stem nut lock nut o
Spring pack gap o
Valve seating / unseating concerns
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High inertia o
High running loads due to packing friction
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o Worm /w cm gear concerns o
Stem / stem nut concerns l
The analyst can also determine the spring pack K-f actor (pounds thrust / spring pack movement), the spring pack preload, and the point of linearity.
A copy of the analyst's results, along with the analyst's recommendations, is given to Nuclear Engineering for review.
The original data sheet is stored in a permanent file.
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o Quality I
MOV Project quality involves everyone associated with the task.
To ensure l
that' quality requirements are met, the Quality Control and Quality Engineering groups perform certain tasks' outlined in relation to the work j
process in the attached flow chart-(Figure 7).
These tasks are described below:
1 Quality Control 1.
Inspection per procedures:
Both the refurbishment and MOVATS testing work plans contain inspection hold points to assure that work tasks are completed and proper parts replacement is accomplished.
2.
Receipt inspection:
Replacement parts are visually inspected for deficiencies in relation to accompanying vendor and SMUD documentation prior to receipt on site.
3.
Questioning of overall process:
Inspectors are often present during refurbishment and testing that does not require Quality Control involvement per procedures.
The inspectors notify Quality Engineering of any condition that does not appear to comply to procedural or good work practice standards.
Quality Engineering-1.
Procedure review:
Refurbishment and MOVATS testing procedures, including revisions, are reviewed for inclusion of necessary j
quality requirements.
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Purchase documentation. review: All QA Class 1 and Commercial Grade purchase of parts are reviewed per the requirements of Quality Assurance Procedure QAP-4.
.3.
' Receipt Inspection Data Report (RIDR) review: -All RIDRs are reviewed to ensure that necessary quality requirements for replacement parts have been verified prior to receipt on site per QAP 4 and 6.
4.
Nonconformance review: All Nonconforming Report (NCR) dispositions and closures are reviewed per the requirements of QAP 17.
5.
Work Request review:
All refurbishment, parts replacement, and MOVATS WRs are reviewed both prior. to and af ter field initiation per the requirements of Administrative Procedure AP3/RSAP-803 1
6.
Engineering Change Notice (ECN) release review:
The ECN release packages are reviewed per AP 44 prior to ECN release to Operations.
7.
Assistance as necessary: Quality concerns presented by QC and o+trr organizations are addressed.
Investigations into specific e V is that could affect the MOV quality, such as engineering
.vplysis, are completed.
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Documentation of Ouality Concerns During the entire work process described above, quality concerns are documented according to existing procedures.
Nonconformances are dispositioned using the Nonconforming Report (NCR).
Any potentially; j
reportable condition which is identified during refurbishment or testing is evaluated using the Occurrence Description Report-(ODR).
Both the NCR and 00R may be initiated by any observer.
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i PROGRAM PRODUCTS
- l The MOV Program has resulted in'several products which may have long-term i
.l application.. These products are summarized in the following paragraphs.
Differential Pressure Determination In order.to determine which MOVs are af fected by the criteria of IEB 85-03, l
a study was conducted on each of the USAR Chapter 14 accidents to identify the MOVs which are required to function in order to mitigate each event.
From this study, the high pressure injection (HPI) and auxiliary feedwater
( AFW) valves required for accident mitigation were identified.
Documentation is available in Ref. 6.
In conjunction with identification of the thirty IEB 85-03 valves, the maximum differential pressure on each valve was determined by evaluating the system parameters for each valve.
Systems involved were the Reactor Coolant system (RCS), Purification and Letdown System (PLS), Seal Injection and Make-up System (SIM), and the auxiliary feedwater portion of the Feedwater System (FWS).
In addition to evaluating the USAR Chapter 14 events, the normal plant operating procedures and the emergency operating procedures were' reviewed to assure the most severe differential pressure operating condition was identified.
Details are found.in Ref. 7.
Differential pressures for MOVs, other than the thirty valves affected by i
IEB 85-03, were developed and documented in References 8, 9, and 10.
The data developed as described in the paragraphs above is used in the engineering work process described previously, i
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'VADIP ComDuter Code Prior to May 1987, thrust calculations were performed by Babcock & Wilcox using a' proprietary program based on the Limitorque sizing manual.
i To enable calculations to be performed in house, Nuclear Engineering has developed a computer code named Valve Actuator Data Input Program (VADIP) which is currently in the validation process.
The VADIP code inputs include valve characteristics, operator characteristics, motor characteristics, system characteristics, and thrust limits.
Using the.Limitorque equations, the. code calculates thrust and torque for several parts of the mechanism, I
.and compares them with allowable values.
These code calculations were validated by means of approved hand calculations, using'the same input data. A printed output will be retained as part of the permanent record.
Calculation Procedures Calculation procedures have been developed to utilize the input data from walkdowns, suppliers, and testing; to analyze the data for engineering evaluation; and to prepare documents which direct the work and testing on the MOVs. These procedures are in the process of being formalized, and will be available for the M0V Program for future use.
SDecial Calculations Calculations were required for special situations.
One example is a seismic.
calculation a.nd pipe support calculation for any case in which the weight or i
center of gravity is af fected by replacing a motor or by replacing both a motor and an operator.
Another example is calculation of allowable thrust l
on a gate valve wedge for a limited number of valve cycles.
This higher allowable thrust could be used temporarily until a stronger wedge (higher l
allowable thrust for the life of the valve) is procured.
This method could be employed for cases of marginal difference between allowable thrust and required thrust.
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L Documentation of MOV Data Documentation of the final configuration of each MOV is accomplished on the E-1012 drawing, entitled-" Motor-0perated Valve Data," with one drawing sheet for each valve. Detailed information is recorded for the, valve, operator, and motor, as well as a listing of reference drawings and documents, with approximately 90 data entries. The E-1012 drawing becomes the permanent record of required switch settings, thrust values, torque values, baseline data. storage address, and limiting component of the assembly.
Referral to the E-1012 drawing is required prior to any future tests or maintenance.of
.the MOV.
i Similarly, valve information, operator information, and motor information are available on the computer-based Master Equipment List (MEL).
Because of the large amount of data and the large number of documents in the program, an MOV Integrated Data Base was implemented.
The data base has the
.following inputs:
i o
Technical data o
Schedule data o
Status o
Document data l
1 Engineering Change Notices j
Nonconforming Reports Occurrence Description Reports Wor.k Requests o
Material data Purchase Requisitions j
The program can be used for data storage and report generation:
o Valve reports o
Document reports o
Material reports 39040 16 9/1/87
i o-Integrated milestone reports o
Integrated special activity reports o
Management summary reports Training Training of mechanical and electrical maintenance personnel is accomplished through development by the Training Department of a training program on Limitorque operators.
Features of the classroom training sessions include:
o Basic' operation o
. Principles of hand and motor operations o
Construction of major subassemblies
.o Lubrication requirements and procedures o
Precautions during removal of operator o
Overhaul: procedures' o
Installation of operators o
Checkout and adjustment of torque switches and limit switches i -
o' Operational retest procedure o
Causes of industry-wide MOV failures Training models (actual Limitorque operators) are used extensively in the training sessions.
On-the-job training supplements the classroom training. The objective of the total training program is task qualification for the crafts.
Task j
qualification.is the ultimate goal of maintenance task training per j
Institute of Nuclear Power Operations (INP0)' guidelines.
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CONTINUATION OF PROGRAM FEATURES i
l Most of the improvements, developments, and innovations will be continued in the MOV Program Plan.
These features have been described above and are summarized here:
o Computerized data storage and engineering calculations.
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Maintenance procedures for refurbishment, testing and analysis, and differential pressure testing.
o Preventive maintenance procedures including trend analysis.
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The E-1012 drawings for controlled documentation of MOV parameters and data.
o The Master Equipment List for computer data base, o
The MOV Integrated Data Base for reference to documentation.
o The training program for engineering and maintenance personnel.
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IEB 85-03 FINAL REPORT PLAN.
IEB 85-03, Item f, requires a written report within 60 days of MOV Program completion.
This report should provide:
(1) a verification of completion of the requested program, (2) a summary of the findings as to valve -
operability prior to any adjustments as a result of this bulletin, and (3) a summary of data in accordance with Table 2 of the bulletin, " Suggested Data Summary Format".
i In accordance with the requirements noted above, a report wil[I be provided l
within 60 days of completion of the program.
An explanation for each phase l
of program completion will be provided to ensure continuity of reported information.
A statement of initial program completion will be contained in i
the body of the report.
The report will cover the 30 plant-specific valves identified for Rancho Seco.
These valves' meet the HPI and AFW system functions addressed by the bulletin.
They have been selected from applicable-portions of the RCS, PLS, SIM, and FWS, based on complete system flow path requirements to perform HPI and AFW functiond.
In addition to
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i pump suction and discharge valve operational requirements to establish flow j
paths for accident mitigation, system requirements for valve closures to isolate unused portions of applicable plant systems were included to ensure f
system integrity during required system operational modes for design base 1
accident mitigation.
Required modes of operation were identified by means of a study of each of the Chapter 14 accidents identified in the USAR.
This j
information was further used in conjunction with information obtained from approved Emergency Procedures and Plant Operating Procedures to identify maximum differential pressures for each of the identifie'd valves.
These motor-operated valves meet the basic bulletin requirements for valve i
selection based on applicable " active" in-service test program motor-operated valves, in the HPI and AFW systems, in accordance with the i
operational readiness test requirements of 10CFR50.55 a(g).
An explanation of these methods of valve selection will be contained within the body of the report with actual valve identification provided by means of an attached 3904D 19 9/1/87
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equipment 'inf o rmation ' table.
This table will further provide requested information. in the form of specific component identification and required-1 operational data as follows:
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1.
. Valve component ID, manufacturer, type, size, ANSI rating, and function; i
2.
Valve operator manuf acturer, model, motor RPM, and overall ratio; j
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Calculated maximum differential pressure values and test values for each valve.
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In addition to providing calculated maximum and actual test differential pressure information for each valve, an explanation of the methods and conditions associated with these values will be provided in support of the information contained in this table.
The following conservative assumptions were used to recalculate the original B&W calculations assuming Safety Feature Actuation System (SFAS) actuation due to low reactor building i
pressure as well as the original low RCS pressure activation assumptions:
1.
No credit was taken for sequence of operation of parallel valves or valves in alternate flow paths which may reduce the maximum pressure imposed upon the motor-operated valve (s) being evaluated.
2.
The system piping losses due to flowing water were assumed to be zero.
3.
'The RCS pressure during full power operation is normally 2155 plus or minus 10 psig as controlled'by heaters.
However, the pressurizer spray is not initiated until 2205 plus or minus 10 psig.
Therefore the normal RCS pressure range is 2145 to 2215 psig.
However, for this evaluation the range of 2155 plus or minus 100 psig, as specified in Operating Procedure 8.3, was used for conservatism relative to RCS letdown and seal injection isolation.
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Minimon make-up tank (Y-235) pressure ws, assumed to be 0 psig with respect to backpressure calculations.
5.
Theconversionfactorusedfogo'nofootofelevationgfwaterwas 2.31 f t/ psi without any assume,1 prepitre reducf,ior's dee to. lower densities.at higher teinperatures.
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6.
Jnc elenvetisn for valves in the same configuration 9as determined using l
the valve ylevation resulting ig more, conservative results, (i.e,
' ighest dif f erential pressure pntential).
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7.
Nap curve T-32265-2 was used fbr.'determinird total discharge head of the make-up/HPI pumps, since the shu:-off head for this pump is the greatest of the three pumps and therefore-the most e. conservative for calculation purposes.
8.
Another conservr,iive assumption based 'on previous events entails the use of worst-case conditions resulting from a make-up tank overfilling event resulting in a recalculated maxiinem opening delta P of 8S psid i
instead nf the originaNy calculat?d 20 p7id f or SFV-27,508.
An explanation of these ' assumptions, and a description of assum6d'and actual plant conditions amt system configuratic.ns will be provided for each valve testeds to allow direct'corparison between calculated conditions /nlues arid actual test conditibns.
A dsta summary of test results/information will be provided by maara cf 6dditional table attachment (s) as required cort.sistent -
with the suggested format cortained in the bulletin. Where c(nditions prohibit testing under actual desigs htse conditions, an exp3anation/
engineering justification will be,proviled to exp?ain the means by which operat1Jity determinations were made. Ih otterall summary of test results anchind[rgswillalsobeprovided'icith!bodyoftherepost.
A justification' will further be prov4ed to explain the ecceptabihty of any test resa?ts, relative to ensured (perational capabliit9 under worst-case coqditions, in the event that the actual test conditions prove significantly inconsistent with the conditions postulated in the calculations.
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With the exception of suction valves, full flow testing at maximum differential pressure and low voltage conditions is planned for each of these 30 valves as practicable. A hydrostatic differential pressure test is planned where practicable for suction valves and any other valves where full flow testing is impractical, to determine cracking loads in the open direction and verify adequate switch settings.
An appendix will be used to provide an explanation of the parameters used to calculate minimum and maximum operator and valve thrust requirements /
capabilities, and the Engineering guidelines used fer general set point j
determinations. A Design Guide is being generated to provide continuity in calculation methods for future valve activities.
A summary of preadjustment findings will be provided to the extent possible by means of information derived f rom initial equipment walkdowns.
l A statement denoting the use of MOVATS test equipment and the planned use of their Motor Load /MCC test unit for long-term performance monitoring will be contained in the body of the report.
This statement will include a description of general program test methods including:
baseline test,
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dynamic test, and low voltage test conditions and limitations.
A description of set point documentation and control methods / procedural actions to ensure present and future controls will be provided in the body of the report.
Other planned report entries include:
an equipment qualification verification statement for motor-operated valves; a summary of position indication actions taken relative to the related concerns expressed in IE Notice 86-29; and a statement of specific control logic changes to correct the operational problems identified for 3-way valves.
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____A
' SCHEDULE-The-following events and submittals are scheduled:
1.- ' All MOV Refurbishment Program ~ work,on 30 IEB 85-03 MOVs and all other safety-related.MOVs:- Completed prior to restart, Ref. 3 and S.
-2.
Final Report on the 30 IEB 85-03 MOVs - Within 60 days of program completion but no later than January 14,1988, Ref.1.
3
.MOV Program completion on all remaining Limitorque MOVs (i.e.170 -
minus M0V's in Item 1)..
l 23 9/1/87 J
REFERENCES 1.
IE Bulletin No. 85-03:
Motor-Operated Valve Common Mode Failures During Plant Transients Due to Improper Switch Settings, November 15, 1985.
2.
Letter, J. E. Ward (SMUD) to J. B. Martin (USNRC), '" Response to IE Bulletin No. 85-03:
Motor-Operated Valve. Common Mode Failures During Plant Transients Due to Improper Switch Settings," JEW 86-023, May 16, 1986.
3.
Letter, J. E. Ward (SMUD) to J. B. Martin (USNRC), " Program Status Summary, Response to IE Bulletin No. 85-03:
Motor-Operated Valve Common Mode Failures During Plant Transients Due to Improper Switch Settings," JEW 86-667, November 5, 1986.
4.
Licensee Event Report 87-06:
Revision 0 transmitted by JEW 87-136 dated February 17, 1987; Revision 1 transmitted by JEW 87-513 dated April 15,1987; Revision 2 transmitted by GCA 87-333 dated July 24, 1987.
5.
Letter, G. Carl Andognini (SMUD) to J. B. Martin (USNRC), "IE Bulletin No. 85-03; Motor Operated Valve Common Mode Failures During Plant Transients Due to Improper Switch Settings," GCA 87-373, July 21,1987.
6.
Phase 2 Program for Compliance to IE8 85-03, B&W Document 51-1164064-01, dated May 12, 1986, SMUD Calculation 2-ZZZ-M2139.
j.
7.
SMUD Differential Pressure Operating Conditions for IEB 85-03, B&W Document 51-1164043-02, dated April 9, 1987, SMUD Calculation Z-ZZZ-M2135.
3904D 24 9/1/87
~8'-
Differential Pressure Evaluation for Task '736 Valves,;8&W Ddcument 51'-1167987-00, dated February 9,1987 SMUD ' Calculation,Z-ZZZ-M2136.
c.
9.-
Differential Pressure Evaluation for Safety-Related Valves Not Covered by Task 701, 8&W Document.51-1167988-00, dated February 9, 1987, SMUD-Calculation Z-ZZZ-M2137.
- 10. - Differential Pressure Evaluation for Nonsafety-Related. Valves, 8&W Document-51-1167989-00, dated February 9,1987, SMUD Calculation
.l Z-ZZZ-M2138.
-l W
3904D 25 9/1/87
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