ML20236X226

Forwards Presentation Handout & Subtask Rept Describing Backflow Test Conducted to Verify Postulated Failure Mode of Accumulator Fill Line & Recovery Action Plan

ML20236X226
Person / Time
Site:	Trojan File:Portland General Electric icon.png
Issue date:	12/03/1987
From:	Chan T Office of Nuclear Reactor Regulation
To:	Office of Nuclear Reactor Regulation
Shared Package
ML20236X228	List: ML20236X226 ML20236X238
References
TAC-65473, NUDOCS 8712090060
Download: ML20236X226 (23)

Text

December 3, 1987

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Decket No. 50-344

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MEMORANDUM FOR: File FROM: Terence L. Chan, Project Manager Prcject Directorate V Division of Reactor Projects - III, IV, V and Special Projects  !

SUBJECT:

ACCUMULATOR FILL LINE FAILURE (TAC 65473) l The attached presentation handout (Enclosure 1) was used by Portland General Electric Company in their presentation to Region V on June 5, 1987.

The licensee's Subtask Report (Enclosure 2) is a description of the back-flow test which was conducted to verify the postulated failure mode of the accumulator fill line.

Also attached is the licensee's Recovery Action Plan on this subject (Enclosure 3). These enclosures should be part of the TAC 65473 file.

original signed by Terence L. Chan, Project Manager Project Directorate V Division of Reactor Projects - III, IV, V and Special Projects Office of Nuclear Reactor Regulation

Enclosures:

As stated DISTRIBUTION:

!Docketlile NRC & Local FCRs PDV Reading TChan GKnighton PD5 .

TChan -

12/ 3 /87 jFJ 28eRSAS!h4 P

A December 3, 1987

% B-Docket No. 50-344-

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liEMORANDUM FOR: File FROM: Terence L. Chan, Project Manager Project Directorate V l Division of Reactor Projects - III, IV, V and Special Projects

SUBJECT:

ACCUMULATOR FILL LINE FAILURE (TAC 65473) l The attached presentation handout (Enclosure 1) was used by Portland General

]

E-,ectric Company in their presentation to Region V on June 5. 1987.

The. licensee's Subtask Report (Enclosure 2) is a description of the back-flow test which was conducted to verify the postulated failure mode of the j accumulator fill line.

1 Also attached is the licensee's Recovery Action Plan on this subject (Enclosure 3).' These enclosures should be part of the TAC 65473 file.

l original signed by Terence L. Chan, Project Manager Project Directorate V Division of Reactor Projects - III, IV, V and Special Projects Office of Nuclear Reactor Regulation

Enclosures:

As stated DISTRIBUTION:

Docket File NRC & Local FDRs PDV Reading TChan l

GKnighton PD5' TChan .

12/ 3 /87

)

Enclosure 1 L. Y x ACCUMULATOR FILL LINE FAILURE CHRONOLOGY AND OPERATIONAL ISSUES - ART OLMSTEAD ENGINEERING ISSUES - ALEX ROI.LER i

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ACCUMULATOR FILL LINE FAILURE 4

CHRONOLOGY MAY 12, 1987: -

"A" ACCUMULATOR FILL LINE FAILS WHILE SLUICING FROM "A" To "D" ACCUMULATOR EVENT REPORT INITIATED PHOTOGRAPHS OF FAILURE MAINTENANCE REQUEST (WORK ORDER) INITIATED NUCLEAR PLANT ENGINEERING (NPE) INFORMED OF FAILURE l

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l ACCUMULATOR FILL LINE FAILURE i CHRONOLOGY k

MAY 13-20, 1987: -

COMPANY METALLURGIST REQUESTED TO EVALUATE FAILURE l

INITIATED AND COMPLETED NONDESTRUCTIVE EXAMINATION  ;

0F OTHER ACCU,MULATOR CONNECTIONS  !

DISCUSSED POSSIBLE FAILURE MECHANISMS WITH NPE ,

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REPLACED PIPING BEIWEEN "A" ACCUMULATOR AND CONTROL i VALVE (CV) 8878A I PRELIMINARY EVALUATION OF FAILURE INDICATES HIGH STRESS-LOW CYCLE FATIGUE CLEARANCE OF SYSTEM RELEASED BY MAINTENANCE i

"A" LINE KER0 TEST AND CONTROL VALVE INSPECTED

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i e ACCUMULATOR FILL LINE FAILURE CHRONOLOGY MAY 20-23, 1987: -

HYDROSTATIC TEST PROCEDURE PREPARED "A" ACCUMULATOR FILLED USING FILL LINE FILL LINE OBSERVED DURING FILL OPERATION - NO MOVEMENT l

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9 ACCUMULATOR FILL LINE FAILURE CHRONOLOGY MAY 23, 1987: -

HYDROSTATIC TEST OF "A" ACCUMULATOR PERFORMED SATISFACTORILY BEGAN SLUICING OPERATION FROM "A" To "D" ACCUMULATOR l VIA FILL LINE OBSERVED WATER HAMMER-LIKE NOISE DURING SLUICIflG FILL LINE BREAKS AT SAME LOCATION IMMEDIATE EVENT REPORT INVESTIGATION.INIIIATED E'0VIPMENT-QUARANTINED -

PERFORMANCE MONITORING / EVENT ANALYSIS (PM/EA) GROUP BEGAN INVESTIGATION ALL SLUICING OPERATIONS PR0HIBITED i

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l r ACCUMULATOR FILL LINE FAILURE CHRONOLOGY.

MAY 24-25, 1987: -

COMPANY METALLURGIST BACK ONSITE TO EVALUATE FAILURE BEGAN NONDESTRUCTIVE EXAMINATION NO NEW PROBLEMS OR DEFICIENCIES IDENTIFIED BLENDED AREAS EXCEED MINIMUM WAl.L MAY 27, 1987: -

ACTIONS COMPLETED TO QUARANTINE OTHER SAFETY INJECTION SYSTEM EQUIPMENT 4

fl e j ACCUMULATOR FILL LINE FAILURE CHRONOLOGY __

MAY 28 -

JUNE 3, 1987: -

HOLD TAGS PLACED ON QUARANTINED EQUIPMENT INSPECTION PLANG PREPARED INSPECTIONS BEGAN ON QUARANTINED EQUIPMENT OPERATING INSTRUCTION (01) 5-2, SAFEIY INJECTION, REVISED DELEIING ALL BACKFLOW OPERATIONS PRELIMINARY STRESS ANALYSIS INDICATES HIGH STRESS AT N0ZZLE TO PIPE INTERFACE VALVE BACKFLOW TEST DEVELOPED AND PERFORMED

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ACCUMULA10R FILL LINE FAILURE OPERATIONAL ISSUES COMPARISON OF AUGMENTED INSPECTION TEAM (All)

GUIDELINES FOR QUARANTINED EQUIPMENT WITH PGE

__ ACTION FOR FAILED SI ACCUMULATOR l AIT GUIDELINES PGE ACTIONS PROCEDURES TO CONDUCI EVENT REPORTING SYSTEM 05/12/87 INVESTIGATION CONFIRMATORY AC110N PLAN PLANT GENERAL MANAGER (PGM) DIRECTED TO FREEZE EQUIPMENT QUARANTINE OF EQUIPMENT 05/23/87 ACl10N PLAN TO DEIERMINE EVENT REPORT SYSTEM USED TO DEVELOP AC110N CAUSE OF FAILURE PLAN TO DEIERMINE CAUSE OF FAILURE 05/23/87 DEVELOP QUARANTINED NUCLEAR PLANT ENGINEERING /0VALITY ASSURANCE EQUIPMENT LIST (NPE/0A) IDENTIFIED EQUIPMENT TO BE ANALYZED VERBALLY TO OPERA 110NS AND MAINTENANCE 05/26/87 QC HOLD TAGS IDENTIFIED EQUIPMENT TO BE PROCEDURALLY CONTROLLED AND INSPECTION (S)

DOCUMENTED 05/28/87 l

ESTABLISH BARRIERS OF OA SIGNED ON CLEARANCE TO CONTROL B0UNDARIES l THE QUARANTINE AREA 05/28/87 GUIDELINES FOR 1ROUBl.E- VALVE DISASSEMBLY PROCEDURES AUCMENTLD BY SH00 LING WORK NPE WRilIEN GUIDANCE AND NPE DIRECI

INVOLVEMENT 05/30/87 1

REPOR1[NG EVENT REPOR1 SYSTEM USED FOR REPOR11NG 05/12/87 8-U _ _ _ - _ _ - _

9 r ACCUMULATOR Fil.L LINE FAILURE OPERATIONAL ISSUES CHANGE ANALY1LS. j l

.10NDIT10NS PREVIOUS PRESENT CONDITIONS CHANGE l 1. SYSTEM INTACT SYSTEM DAMAGED SLUICE FROM "A" l ACCUMULATOR T0 "D" l ACCUMULATOR VIA FILL l LINE

2. SYSTEM DANGER TAGS REMOVED FOR HYDRO- NO CLEARANCE I TAGGED (CLEARED) STATIC TEST l

3. SLUICE THROUGH SLUICE THROUGH FILL CLEARANCE ON SAMPLE

! SAMPLE LINES LINES LINES (LAGGED OU1) l USING 1 INCH LINE VERSUS 3/L1 INCH Lt . REVERSE FLOW REVERSE FLOW THROUGH No CHANGE THROUGH KER0 TEST KER0 TEST VALVE VALVE

5. OPERATIONAL OAR FOUND IN FILES No CHANGE ASSESSMENT REPORT WITH No ACTION TAKEN (OAR) 1DENTIFIED BUT WAS NOT COMMUNICATED i

6. WATER LEVELS "A" ACCUMULATOR SOLID DECREASE IN NORMAL EXPANSION SPACE 1

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7. LOW DIFFERENTIAL DP = 650 PSI INCREASE IN FLOW PRESSURE (DP) VELOCITY BEIWF.LN' lANKS

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f. r-ACCUMULATOR FILL LINE FAILURE OPERATIONAL ISSUES l 1 l

ENERGY-BARRIER-TARGEllNALY1LS l LESS THAN

ENERGY BARRIER ADE0UAIL AD_E011 AIL. NOT U Sell TARGET PRESSURIZED SEISMIC X REACTOR ACCUMULATOR PIPING CORE NDP 600-2 X PERSONNEL WATER HAMMER 01 5-2 X A0 3-9 X HANGERS X COMMUNICA- X TION OAR'S X DESIGN X (NORMAL)

DESIGN X (BACKFLOW)

MANAGEMENT X POLICY l

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.I e ACCUMULATOR FILL.LINE FAILURE l

l OPERATIONAL ISSUES FINDINGS

1. COMMUNICATIONS INADEQUATE W11HIN OPERATIONS BRANCH i

BETWEEN OPERATIONS AND SYSTEM ENGINEERS FROM OPERATIONAL EXPERIENCE REVIEW PROGRAM (GERP)

2. PROCEDURES 01 2 DEVI Al [0N WI IHOU T APPROVAL I

POLICY FOR OPERATING EQUIPMENT DURING REFUELING / MAINTENANCE NOT CLEAR 01-5-2 PERMllTED REVERSE FLOW THROUGH PACKLESS DIAPHRAGM GLOBE VALVES VIA SAMPLE LINES NONCONFORMANCE REPORT (NCR) PROCEDURE NOT CLEAR ON WHEN HOLD TAGS ARE REQUIRED

3. CONTROL ROOM LOGS LACK SPECIFICITY AND COMPLETENESS.

4. MAINTENANCE REl. EASED CLEARANCE AFIER REPAIR WORK WAS COMPLETED, LOSING CONIROL OF SYSTEM.

5. PLANT PIPING AND INSTRUMENT DRAWINGS (P&lDS) DO NOT PROVIDE ALL INFORMAL [0N NECESSARY TO WRITE PROCEDURES.

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ACCUMULA10R FII.L LINE Fall.URE OPERATIONAL-ISSUES _

SUMMARY

OF CORRECTIVE AClIONS

1. DEVELOP BETTER VERTICAL AND HORIZONTAL COMMUNICATIONS WITHIN AND OUTSIDE OPERATIONS DEPARTMENT.

2. PROVIDE TRAINING ON POLICY REGARDING PROCEDURAL COMPLIANCE.

3. PERFORM OUALITY ASSURANCE SURVEILLANCE OF THE OPERATIONAL EXPERIENCE REVIEW PROGRAM (OERP).

4. IMPROVE CONTROL ROOM LOGS.

5. REVISE NCR PROCEDURE TO PROVIDE DEIAILED CRIIERIA FOR HOLD 1AGS.

6. REVISE WORK ORDER PROCEDURE TO PROVIDE REQUIREMENTS FOR CONTROL 0F SYSTEMS BEIWEEN REPAIR AND CLOSEOUT OF ACCEPTABLE TESTING AND EVALUATIONS.

7. REVIEW ALL PROCEDURES TO ENSURE NO OTHER BACKFLOW OPERAll0NS ARE PERMITTED FOR PACKLESS DIAPHRAGM GLOBE VALVES.

f. r ACCUMULATOR FILL LINE FAILURE ENGINEERING _ ISSUES INSPECTIONS ANALYSES ROOT CAUSES CORRECTIVE ACTIONS l

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ACCUMULATOR FILL LINE FAILURE ENGINEERING. ISSUES ,

INSPECTIONS SURFACE EXAMINATIONS ON:

ALL N0ZZLE-10 'IPE P WELDS FILL LINE PIPE WELDS FROM ACCUMULATOR 10 SECOND SUPPORT UPSTREAM 0F CONTROL VALVE SAMPLE LINE PIPE WELDS ABOUT 10 FEET ON EITHER SIDE OF SAMPLE LINE PACKLESS DIAPHRAGM GLOBE VALVES

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FILL LINE SLUICING PATHWAY FROM "A" TO "D" ACCUMULATOR l

RESULTS INDICATION ON "B" ACCUMULATOR INJECTION LINE N0ZZLE SCAB ON "B" ACCUMULATOR INJECTION LINE INDICATION ON "D" ACCUMULATOR INJECTION LINE N0ZZLE INDICATION ON FILL LINE FOR "B" ACCUMULATOR ULTRASONIC EXAMINATIONS N0ZZLE-TO-VESSEL WELD ON "A" ACCUMULATOR RIDGES ON "C" ACCUMULATOR FILL LINE TO DETERMINE WALL THICKNESS VISUAL PIPE SUPPORTS ON FILL LINES FOR ALL ACCUMULATORS CONTROL VALVES AND PACKLESS DIAPHRAGM GLOBE VALVES ON SAMPLE AND FILL LINES SMALL PIPING IN CONTAINMENT WITH PACKLESS DIAPHRAGM GLOBE VALVES ,

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ACCUMULATOR FILL LINE FAILURE ENGINEERING ISSUES ANALYSES:

METALLURGICAL ANALYSIS OF FAILURE DYNAMIC ANALYSIS OF SLUICING OPERATION DETERMINE FLOW RATES BACKFLOW THROUGH PACKLESS DIAPHRAGM GLOBE VALVES OTHER APPLICATIONS INDUSTRY EXPERIENCE N0ZZLE-TO-VESSEL WELD STRESSES ON "A" ACCUMULATOR TEST CONDUCTED AT BOARDMAN l

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ACCUMULATOR FILL LINE FAILURE ENGINEERING ISSUES ROOT CAUSES HIGH BACK FLOW THROUGH KER0 TEST VALVES CORRECTIVE ACTIONS EVALUATE APPLICATIONS AND USE OF PACKLESS DIAPHRAGM GLOBE VALVES PR0HIBIf SLUICING OPERATIONS

- _ _ _ - _ _ _ _ _ _ _ -