ML20234E978
| ML20234E978 | |
| Person / Time | |
|---|---|
| Site: | North Anna  |
| Issue date: | 01/04/1988 |
| From: | Stewart W VIRGINIA POWER (VIRGINIA ELECTRIC & POWER CO.) |
| To: | NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM) |
| References | |
| 86-275A, IEB-85-003, IEB-85-3, NUDOCS 8801110279 | |
| Download: ML20234E978 (28) | |
Text
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i VIRGINIA ISLECTRIC AND POWEH Com%M*
R ICit M O ND, VING IN I A 2i32 61 W.L,STswAwT vic e...w..T January 4, 1988 N :cLaam OrzRATIONN United States Nuclear Regulatory Commission Serial No.
86-275A Attention: Document Control Desk N0/RCB:jmj Washington, D.C.
20555 Docket Nos.
50-338 50-339 License Nos. NPF-4 NPF-7 Gentlemen:
VIRGINIA ELECTRIC AND POWER COMPANY NORTH ANNA POWER STATION UNITS 1 AND 2 RESPONSE TO IE BULLETIN 85-03 MOV COM)N MODE FAILURES DURING PLANT TRANSIENTS DUE TO IMPROPER SWITCH SETTINGS As requested by IE Bulletin 85-03, the Virginia Electric and Power Company has implemented a program to ensure that valve operator switches are selected, set and maintained properly.
Motor operated valves (MOVs) in the high pressure safety injection and auxiliary feedwater systems which are required to be tested for operational readiness in accordance with 10 CFR 50.55a (g) have been fully integrated into a new MOV program similar to the MOVATS " Blue Book" program.
Programmatic and procedural enhancements will be implemented as
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required.
1 is a summary of the North Anna program and is divided into the following five sections:
I.
Results of design basis review.
II.
Policies for establishing correct switch settings.
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III. Switch adjustments and demonstration that valves will function l
properly during both normal and abnormal events within the design basis.
IV. Summary as to valve operability prior to adjustments as a result of IEB 85-03.
V.
Data summary.
8801110279 880104 D
{DR ADDCK 05000338 I
____ _J
Attachments 2 and 3 summarize the calculations used to determine required thrusts.
The information provided in this response is true and accurate to the best of my knowledge.
If additional information is required, please let me know.
Very truly yours, W. L. Stewar't Attachments cc:
U. S. Nuclear Regulatory Commission l
101 Marietta Street, N.W.
Suite 2900 Atlanta, GA 30323 Mr. J. L. Caldwell NRC Senior Resident Inspector North Anna Power Station
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Meachment 1
? age 1 of 24 i
I, RESULTS OF DESIGN BASIS REVIEW
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The following is a discussion of the basis for selecticn of ROVs, the method of determining maximum differential pressure expected' durir'.g-opening and closing, and the design basis differential pressure for each MOV.
1.
HIGH PRESSURE SAFETY JN.JECTION The subject high presw.re safety injeet1,ott MOVs are listed in Table 1.
The MOV select 16n is based on M0h in the initial 11ne up of high pressttre safety ~ injection.
The initial line up of high pressure l
safety injection at the North Anna Power Station Units _ 1.and, 2
consists of the chacgitig pumps taking suction from the refueling water storage tank (RkST) and discharging to the Beactor Coolant System cold legs via the boron injection tank.
The MO7e included 1:t Table'I are I
the MOVs required to realign the charging pumps from normal charging t
to high pressure safety injection and MOVs which if' inadvertently j
opened or closed would isolate safety injection (SI).
Additionally, bued on.the' NRC Request f'or Additional Information dated September 18,
- 1987, che charging pump mini-flow valves l
(1275/2275 A, B, C and 1373/2373) were a.ided to the scope of IEB 85-03 I
work.
Based on a review of the;oystem realignment, the maximum differential pressure across the charging pump discharge MOVs is based on the i
L raximum charging purg discharge pressure on the up. stream side of the i
l valve and a zero pu'g pressure on the downstream side. This condition could exist for a LOCA where the RCS pressure drops to zero and the charginF pumps are stdrted on a SIS signal or for a.line break dm natream of the valva. Stace this is the worst case dif ferential pressure per review of the UFSAR accident analysis, emergency procedures, and system. configuration, this differential pressure bounds all opening and closing design basis events for the high pressure safety injection diccherge valves. The maximum differential pressure across the MOVs in the saction lines to the charging pumps is-based on the mexfrum prenaura:from the RWST or volume control tank (VCT) and the diccharge pressure of the low head safety injection
)
pumps when discharging to'the charging pump suction for the low-head Si pump to high-head SI pump isolation val es.
l Tl e dif M ential ' pressure for the charging putap mini-flow ret?rculation. valves (1275/2275 A,
B, C and 1373/2373) is based dri shuto'f head c f the charging pumps (taking suction; from the t i.HSI pumps) c.,d zer, presnure downstream of the MOV for 6perdng c1ke valves following inahrrtent shutting or 1275 psig in the RCS tbr shutting the valves as required by 1-EP-0.
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Page 2 of-24 2.
The subject. auxiliary feedwater MOVs are listed in Table 1.
The MOV selection is based on MOVs in the line up of the auxiliary feedwater to the steam' generators. The auxiliary feedwater systems at the North l
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Anna Power Station Units 1 and 2 consist of one steam driven and two motor driven auxiliary feedwater pumps per unit which take suction from the two 110,000 gallon emergency condensate storage tanks and discharge to the steam generator teedwater lines.
The MOVs listed in Table.1 are the MOVs in the discharge lines which, if. inadvertently 1
closed, could isolate auxiliary feedwater.
These MOVs.are normally open and remain open but may be throttled to control flow as required during an event. If these valves were inadvertently closed however, they would require reopening. Also, these MOVs would be closed to j
isolate a break downstream (feedwater line break) of the MOVs to
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prevent loss of' auxiliary feedwater through the break.
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Based on a review of the system configuration, the maximum j
differential pressure across the MOVs is the discharge' pressure of the
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auxiliary.feedwater pumps on the upstream side of the valves and zero psig downstream due to a line break downstream of the MOV.
The review of the UFSAR accident analysis, emergency procedures, and system operation confirms that this differential pressure bounds all opening I
.and closing derign basis events for the auxiliary feedwater MOVs.
3 The maximum differential pressure for each MOV is listed in Table 1.
I Table 1 also provides the valve mark numbers and functions.
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Page 3 of 24 TABLE I MAXIMUM DIFFERENTIAL PRESSURE
SUMMARY
NORTH ANNA UNITS 1 AND 2 DESIGN VALVE VALVE FUNCTION BASIS DP 1115B, D RWST to high-head SI pump isolation 36 psi 2115B, D 36 psi 1115C, E VCT to charging pump isolation 80 psi 2115C, E 80 psi 1267A, B Low-head SI to high-head SI isolation 180 psi 2267A, B 180 psi 1269A, B 180 psi 2269A, B 180 psi 1270A, B 180 psi 2270A, B 180 psi
)
1286A, B, C Charging pump to normal charging isolation 2740 psi 2286A, B, C 2740 psi 1289A, B Charging pump to normal charging isolation 2636 psi 2289A, B 4-~~~
2636 psi 1867A, B, C, D High-head FI to cold leg isolation 2636 psi 2867A, B, C, D 2636 psi FW-100B, D Auxiliary steam generator feedwater pump 1406 psi FW-200B, D to steam generator 1406 psi 1275A, B, C Charging pump recirculation to seal water open - close heat exchanger 2297 psi close-open 2737 psi 2275A, B, C open - close 2297 psi close-open 2737 psi 1373 2740 psi g
4 2373 2740 psi
Page 4 of 24 II.
POLICIES FOR ESTABLISHING CORRECT SWITCH SETTINGS This section defines the technical basis for establishing torque switch, limit switch, and thermal overload relay settings.
The basis for many of these policies was obtained from M0 VATS Incorporated who compiled test data from many plants to provide technical justification for several alternate policios for
- torque, torque bypass, and limit switch setting methods.
- c and limit switch settings were verified using MOVATS signature analysis methods.
The following is a summary of the methods used to select switch settings for IEB 85-03 MOVs at North Anna Power Station:
OPEN/CLOSE TORQUE SWITCH Torque switch settings were chosen to achieve the minimum thrust required to operate the valves against design maximum differential pressure.
The calculated thrust (below) is a
conse rva tive summation of the valve stem thrust due to differential pressure, the packing load, and the stem unbalance load (due to piston effect of the stem if applicable).
The minimum required thrust was determined by picking the greater of the following (except as noted):
1.
MOVATS provided required thrust (see Data Summary Table Two).
2.
Required thrust from the valve manufacturer (if available) or from industry standard calculations.
The following tolerances were added to the minimum required thrusts (above) to establish the minimum target thrusts.
1.
Ten percent (fifteen percent for values below 4000 lb.) was added to the calculated (or valve manufacturer provided) thrusts to account for test equipment inaccuracies and equipment repeatabilities.
2.
Ten percent (fif teen percent for values below 4000 lb.) was added to the MOVATS provided thruet unless otherwise noted to account for the above inaccuracies and repeatabilities as well as an additional five l
percent safety factor which was recommended by MOVATS.
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Additionally, thrust values were reviewed to ensure that GDC-17 reduced voltage maximum thrusts were not exceeded.
OPEN LIMIT SWITCH The open limit switches were adjusted as required to prevent backseating. Typically, the open limit switches were set to approximately 90 to 95 percent of stroke from the fully closed position.
Since the amount of stem travel is affected by the inertia of the MOV assembly, valve design, and motor contactor drop out time, the following process was used to set the open limit switches.
The limit switches were set initially for 90 to 95 percent of the full open stroke.
After opening the valves electrically, the valves were cycled (handwheeled) open manually to verify that they were fully open (less than five percent from the backseat) but that they were not backseated.
If a valve was found to be backseating, the open limit switch was adjusted and the adjustment was rechecked as described above.
Page 5 of 24 CLOSE LIMIT SWITCH The following IEB 85-03 MOVs were adjusted to limit shut (limit switch and torque switch in series):
1-CH-MOV-1115B, D 2-CH-MOV-2115B, D i
These MOVs are fast acting and have Limitorque SB-00 operators. Because of the speed of these operators, the operators developed significantly more closing thrust than required. Due to the design of the SB-00 operators, this thrust was stored in the spring compensator and could be released when the operator was declutched for manual operation causing wear of the hypoid gear and creating a personnel hazard due to the spinning handwheel. Based on a recommendation from Limitorque, the control circuits for these operators were modified by a SNSOC approved EWR to place the close limit switch in series with the close torque switch.
The limit switches were then adjusted to open after the valve disk contacted the seat but before the clore torque switches tripped, resulting in a significant reduction in total thrust. For the remaining MOVs the close limit switch was not in the control circuit.
NOTE: Valves 2-CH-MOV-2289B and 2-CH-MOV-2373 (Westinghouse valves) were previously modified for limit closure.
CLOSE-TO-OPEN TORQUE SWITCH BYPASS (See Figures 1
and 2)
Close-to-open torque switch bypasses were relocated to LS-13 (Rotor 4) and set to bypass the open torque switch for a minimum of 20 to 25 percent of stroke time from the beginning of unseating.
Valves which receive a safety signal to open ware bypassed 80 to 85 percent of stroke time from the beginning of unseating as an additional measure of conservatism.
See Figures 3 through 5 for typical elementary diagrams before and after modifications.
Since the close-to-open torque switches for all IEB 85-03 MOVs are bypassed during unseating, maximum pullout torque is available during unseating.
OPEN-TO-CLOSE TORQUE SWITCH BYPASS The open-to-close torque switch bypasses were typically set to the same position as the open limit switch.
As an additional measure of conservatism for those MOVs which receive a close safety signal the open-to-close torque switch bypass was moved to LS-9 (Rotor 3) and adjusted to bypass approximately 80 to 85 percent of stroke. See Figures 3 through 5 for typical wiring changes.
THERMAL OVERLOAD RELAYS Thermal overload relays were sized to allow approximately ten seconds of operation at locked rotor to ensure the MOVs would not be precluded from operating by inadvertent thermal overload trips.
IEB 85-03 overload settings were reviewed to ensure that cable protection was maintained and that uncertainties were resolved in favor of the MOVs performing their safety functions.
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Page 6 of 24 III. SWITCH ADJUSTMENT AND DEMONSTRATION THAT VALVES WILL FUNCTION PROPERLY DURING BOTH NORMAL AND ABNORMAL EVENTS WITHIN THE DESIGN BASIS IEB 85-03 torque and limit switch adjustments have been completed and verified using MOVATS Signature Analysis. Torque switches were set to trip at a value greater than the thrust required to overcome differential pressure as described in Section II.
The initial POVATS signature analysis for the North Anna IEB 85-03 MOV program consisted of stem thrust signatures and calibration, torque and limit switch signatures, and motor load signatures for each affected MOV.
To demonstrate that IEB 85-03 MOVs would operate against design basis differential pressure, North Anna utilized a method developed by MOVATS. This method (the " Blue Book" program) employed MOVATS equations for different types of valves based on actual differential pressure test data.
Examples of these equations are shown in Attachment 2.
Additional differential test pressure testing was not considered necessary as long as the valve types were included in the MOVATS industry data. Valves were considered included in the MOVATS data unless one or more of the following conditions existed:
1.
The industry data did not encompass the particular size of valve being evaluated.
2.
The valve was of a unique or unusual design, such that the data base information did not apply.
3.
Sufficient industry full or partial pressure test data was not available at the time of the plant test to validate the equation being used for thrust calculations.
The industry data base was considered sufficient to validate the MOVATS equation if at least four sets of pressure data existed for the same type and size of valve or twenty sets for the same type but various sizes.
Based on the above criteria, the MOVATS data base was not considered sufficient to validate the MOVATS equations for two valve types including the following valves:
FISHER 3" GLOBE VALVES l
1-FW-MOV-100B 2-FW-MOV-200B I
1-FW-MOV-100D 2-FW-MOV-200D ALOYC0 6" VENTURI CATE VALVES 1-Cll-MOV-1267 A 2-CH-MOV-2267A 1-CH-MOV-1267B 2-CH-MOV-2267B 1-CH-MOV-1269A 2-CH-MOV-2269A 1-CH-MOV-12 69 B 2-CH-MOV-2269B 1-CH-MOV-1270A 2-CH-MOV-2270A 1-CH-MOV-1270B 2-CH-MOV-2270B
Page 7 of 24 In order to verify the calculations used for the valves listed above, the following additional differential pressure testing was performed:
1-FW-MOV-100B This MOV was instrumented with MOVATS signature analysis equipment and cycled open and then closed against the discharge of the auxiliary feedwater pump (1420 psig) with the steam generator vented to atmosphere.
The maximum differential pressure based on the difference in elevation between the valve and the final level in the steam generator was 1406.5 psid (this is conservative since the lower initial level in the generator actually resulted in a greater differential pressure). The maximum thrust required to stroke the valve in both directions was less than the 1300 lb.
preload of the spring pack.
Since the thrust required was less than the spring pack preload and could not be measured exactly (other than less than 1300 lb.) a minimum required thrust was established for the remaining identical MOVs by adding to 1300 lbs the design worst case packing load of 320 pounds (for Grafoil packing),
a fifteen percent (15%) tolerance for instrument accuracy (including the torque switch), and a twenty-five percent (25%) engineering safety factor, resulting in 2329 lbs. required thrust as shown below:
Required thrust = (1300 lb. + 320 lb.) x 1.15 x 1.25 - 2329 lbs.
Due to the conservatism in the above test and calculation, as well as the fact that the close-to-open torque switch bypass for 1-FW-MOV-100B, D and 2-FW-MOV-200B, D were adjusted to bypass approximately 20 - 25 percent of valve stroke from the beginning of unseating, no further differential pressure testing was deemed necessary to ensure that these valves would operate against design basis differential pressure.
1-CH-MOV-1267A 1-CH-MOV-1269A, B 1-CH-MOV-1270A These valves were instrumented with MOVATS signature analysis equipment and opened against a differential pressure of 180 psig. All MOVs opened satisfactorily. The maximum thrust required to overcome the differential pressure was 1300 lbs. based on test data analysis performed by MOVATS.
Based on the results of this differential pressure, MOVATS hus determined that these valves required 1560 lbs.
of thrust to operate against the uaximum design differential pressure.
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Page 8 of 24 As a means of future monitoring of the thrust available to operate the valves against differential pressure, MOVATS base line " Motor Load" signatures were obtained for each IEB 85-03 MOV.
These signatures, which can be related directly to changes in stem thrust, have been forwarded to M0 VATS Inc. for determination of motor load " threshold" values.
The motor load threshold is determined where possible by conservatively calculating the stem thrust required to overcome differential pressure and by measuring the corresponding motor load value.
Motor load values recorded during trouble shooting or post maintenance tests will be compared to the baseline signatures and to the established threshold values (if available) to ensure that valve reliability has not been affected and to determine what additional testing, if any, is required.
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Page 9 of 24 IV.
SUMMARY
AS TO VALVE OPERABILITY PRIOR TO ADJUSTMENTS AS A RESULT OF IEB 85-03 The following "as found" condition summary is based on a comparison of the "as found" thrust and the thrust' required to operate against maximum design differential pressure:
1-CH-MOV-1115B, C, D, E 2-CH-MOV-2115B, C, D, E 1-CH-MOV-1267A, B 2-CH-MOV-2267A,B 1-CH-MOV-1269A, B 2-CH-MOV-2269A, B 1-CH-MOV-1270A, B 2-CH-MOV-2270A,B 1-CH-MOV-1275A, B 2-CH-MOV-2275B 1-CH-MOV-1286C 2-CB-MOV-2286B 1-CH-MOV-1289B 2-CH-MOV-2289A, B 1-W-MOV-100B 2-W-MOV-200B, D 1-FW-MOV-100B 2-SI-MOV-2867A, D The valves listed above were considered fully operable prior to adjustment since the "as found" thrust was greater than th'e required thrust and no significant abnormalities were noted during MOVATS testing.
All valves satisfactorily completed their last stroke time test.
2-CH-MOV-2275C Although the "as found" thrust for this MOV was below the thrust required (from Data Summary Table Two) the valve was considered operable based on the following:
1.
No significant degradations or abnormalities were noted during MOVATS testing.
2.
The valve satisfactorily passed its last stroke time' test.
3.
The open torque switch was bypassed for approximately eight percent of valve stroke after unseating.
4.
The "as found" closing thrust was well above the calculated thrust required.
1-CH-MOV-1286A, B 2-CH-MOV-2286A, C Although the "as found" thrust for the above listed MOVs was below the thrust required
(. from Data Summary Table Two), all valves were considered operable based on the following:
1.
No significant degradations or abnormalities were noted during MOVATS testing..
2.
All valves satisfactorily completed their last stroke time test.
3.
These MOVs are normally open and would be required to open only if they were inadvertently shut.
4.
The "as found" open-thrust vclues (measured above running load) were either-above the required thrust or a significant portion of the
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close-to-open stroke.was bypassed.
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Page 10 of 24 1-CH-MOV-1275C Although the "as found" thrust in the open direction was below the M0 VATS required thrust, the valve was considered operable based on the following:
q 1.
No significant degradations or abnormalities were noted during MOVATS testing.
2.
The valve satisfactorily performed its last stroke time test.
3.
The valve had more thrust available to open than the required thrust calculated in accordance with Attachment 3.
1-CH-MOV-1289A 1-SI-MOV-1867A, B, C 2-SI-MOV-2867C Although the "as found" thrust for the above listed MOVs was below the thrust required (from Data Summary Table Two), all valves were considered operable based on the following:
1.
No significant degradations or abnormalities were noted during MOVATS testing.
2.
All valves satisfactorily completed their last stroke time test.
3.
These valves are precluded from inadvertent operation with an SI signal present until SI is reset at which time they can be repositioned by the operator.
4.
The expected differential pressure for these MOVs based on the low pressurizer precsure safety injection actuation setpoint of 1765 psig is 871 psid (v.s 2636 used in the calculations).
Based on this value, a stem force of approximately 2746 lbf (MOVATS equation)/ 1905 lbf thrust above packing load (Industry Equation) would be required to operate against this differential pressure.
Since all of these MOVs had well in excess of 2800 lbf available at the "as found" torque switch
- settings, the valves were considered operable prior to adjustment.
1-CH-MOV-1373 Although the "as found" open thrust was below the thrust required (from Data Summary Table Two),
the valve was considered operable based on the following:
1.
The valve satisfactorily completed its stroke time test.
2.
The close-to-open torque switch bypass was found at 10%.
3.
The "as found" close thrust was above the calculated thrust required by both the MOVATS and industry standard calculations.
1 Page 11 of 24 1-FW-MOV-100D Although the "as found" thrust (based on torque switch settings) for this MOV was greater than the required thrust, a problem was noted in the stem connector block which allowed the valve operater stem to unscrew from the stem connector block when the valve was manually opened against the
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backseat. The problem was corrected by adjusting and pinning the connector 1
block per a SNSOC approved Engineering Work Request.
This MOV was considered operable prior to adjustment based on the following:
1.
The valve satisfactorily completed its stroke time test.
I 2.
The operator did not unscrew from the connector block when operated manually except when backseating.
3.
Based on the differential pressure test of FW 100B, the actual thrust required to operate against maximum design differential pressure (less j
than 1300 lbf) is significantly less than the calculated (required)
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stem thrust of 2329 lbf.
1-SI-MOV-1867D The "as found" thrust for this MOV was significantly below the required (calculated) thrust and the valve failed its periodic test prior to adjustment.
This valve was not considered operable prior to adjustment.
2-CH-MOV-2373 While the "as found" open thrust was below the calculated thrust (from Data Summary Table Two), the valve was considered operable prior to adjustment based on the following:
1.
The valve satisfactorily completed its last stroke time test.
2.
The open thrust available at torque switch trip was above the required thrust calculated by MOVATS.
3.
The valve was limit shut (no torque sv!tch in the close circuit) prior to adjustments or modifications as a result of this bulletin.
2-CH-MOV-2275A 2-SI-MOV-2867B Although these valves had satisfactorily passed their stroke time tests prior to valve testing for IEB 85-03, the operability of these valves prior to adjustment cannot be verified based on the low "as found" thrusts.
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_F.IGURE 4 TYPICAL WIRING FOR VALVES WITH EITHER AN OPEN SAFETY SIGNAL OR NO SAFETY SIGNAL 1
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Page 1 of 1 MOVATS REQUIRED THRUST EQUATIONS Factors:
Seat Face Load (SL) = (0.3) (DP x Orifice Area)
Wedging Load (WL) = (.75) (SL)
Piston Effect (PE) = (DP x Stem Cross-Section Area)
Scaling Constant (SC) = 1.3 Gate Valves:
DP Opening Thrust (OT) = (SC) (SL + WL)
DP Closing Thrust (CT) = (SC) (SL + PE)
DP Opening Thrust (OT) = (SC) (SL)
DP Closing Thrust (CT) = (SC) (SL + PE)
Minimum Thrust (above running load)
Minimum Required Open Thrust = (1.15 x OT) for OT greater than 4000 lbs
= (1.2 x OT) for OT less than 4000 lbs Minimum Required Close Thrust = (1.15 x CT) for OT greater than 4000 lbs
= (1.2 x CT) for OT less than 4000 lbs NOTE:
The following MOVs were reviewed separately by M0 VATS and the required thrust values were determined based on test data for similar valves.
These MOVs may not fit the above general valve equation:
CH-1275A,B,C CH-2289B CH-2275A,B,C CH-2373
m Page 1 of 1 INDUSTRY STANDARD CALCULATIONS The thrust required to open or close a gate or globe valve is the thrust necessary to overcome the following three forces:
Stem thrust or frictional force (Tf)
Packing Load (Lp)
Stem unbalance load (Ls)
The stem thrust is caused by the differential pressure (DP) across the valve or disc which forces the disc against the seat.
This load is normal to the direction of the valve stem thrust.
The frict.fon between the disc and the seat caused by this pressure load is overcome by the stem thrust.
Stem thrust (Tf) = DP x AS x fv i
Where: As
= seat area fy = valve factor (dependent upon valve type)
DP = maximum design differential pressure The packing load (Lp) is the drag created by the valve stuffing box on the stem.
These values are based on experience and stuffing box design and are obtained from Limitorque or the valve manufacturer.
The stem unbalance load (Ls) is the load required when the system operating pressure (Po) working against the stem area (Ao) forces the stem toward the opening direction since it is not balanced externally.
Stem Unbalance Load (Ls) = Po x Ao The total required thrust (T) is the sum of the three forces described above.
T = Tf + Lp + Ls NOTE:
Although stem unbalance load is always present in gate valves it is not always present in globe valves. A more appropriate equation for a globe valve is Ls (stem area x line pressure - stem area x
=
differential pressure).
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