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| | issue date = 10/04/2011 | | | issue date = 10/04/2011 |
| | title = IR 05000255-11-012, on 08/15/2011 - 09/01/2011, Palisades Nuclear Plant, Inspection Procedure 93812, Special Inspection | | | title = IR 05000255-11-012, on 08/15/2011 - 09/01/2011, Palisades Nuclear Plant, Inspection Procedure 93812, Special Inspection |
| | author name = West S K | | | author name = West S |
| | author affiliation = NRC/RGN-III/DRP | | | author affiliation = NRC/RGN-III/DRP |
| | addressee name = Vitale A | | | addressee name = Vitale A |
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|
| =Text= | | =Text= |
| {{#Wiki_filter:UNITED STATES NUCLEAR REGULATORY COMMISSION REGION III 2443 WARRENVILLE ROAD, SUITE 210 LISLE, IL 60532-4352 October 4, 2011 Mr. Anthony Vitale Vice-President, Operations Entergy Nuclear Operations, Inc. | | {{#Wiki_filter:October 4, 2011 |
|
| |
|
| Palisades Nuclear Plant 27780 Blue Star Memorial Highway Covert, MI 49043
| | ==SUBJECT:== |
| -9530
| | PALISADES NUCLEAR PLANT |
| | |
| SUBJECT: PALISADES NUCLEAR PLANT | |
| - NRC SPECIAL INSPECTION TEAM (SIT) REPORT 05000255/2011012 | | - NRC SPECIAL INSPECTION TEAM (SIT) REPORT 05000255/2011012 |
|
| |
|
| ==Dear Mr. Vitale:== | | ==Dear Mr. Vitale:== |
| On September 1, 2011, the United States Nuclear Regulatory Commission (NRC) completed a special inspection at your Palisades Nuclear Plant. The inspection was conducted in response to the circumstances surrounding the failure of the Service Water Pump P | | On September 1, 2011, the United States Nuclear Regulatory Commission (NRC) completed a special inspection at your Palisades Nuclear Plant. The inspection was conducted in response to the circumstances surrounding the failure of the Service Water Pump P-7C, on August 9, 2011. Based on the risk and deterministic criteria specified in Management Directive 8.3, "NRC Incident Investigation Program," a special inspection was initiated in accordance with Inspection Procedure 93812, "Special Inspection." |
| -7C, on August 9, 2011. Based on the risk and deterministic criteria specified in Management Directive 8.3, "NRC Incident Investigation Program," a special inspection was initiated in accordance with Inspection Procedure 93812, "Special Inspection." | |
|
| |
|
| The special inspection charter (Attachment 2 of the enclosure) provides the basis and focus areas for the inspection. | | The special inspection charter (Attachment 2 of the enclosure) provides the basis and focus areas for the inspection. |
|
| |
|
| The enclosed inspection report documents the inspection results, which were discussed with you and other members of your staff at the exit meeting on [[Exit meeting date::September 1, 2011]]. | | The enclosed inspection report documents the inspection results, which were discussed with you and other members of your staff at the exit meeting on [[Exit meeting date::September 1, 2011]]. |
| The determination that the special inspection would be conducted was made on August 15, 2011, and the on | | The determination that the special inspection would be conducted was made on August 15, 2011, and the on-site inspection commenced the same day. |
| -site inspection commenced the same day. | |
|
| |
|
| The inspection examined activities conducted under your license as they relate to safety, compliance with the Commission's rules and regulations, and with the conditions of your license. The inspectors reviewed selected procedures and records, conducted field walkdowns, and interviewed personnel. | | The inspection examined activities conducted under your license as they relate to safety, compliance with the Commission's rules and regulations, and with the conditions of your license. The inspectors reviewed selected procedures and records, conducted field walkdowns, and interviewed personnel. |
|
| |
|
| Based on the results of this inspection, no findings of significance were identified. In accordance with 10 CFR 2.390 of the NRC's "Rules of Practice," a copy of this letter, its enclosure, and your response (if any) will be available electronically for public inspection in the NRC Public Document Room and from the Publicly Available Records (PARS) component of NRC's document system, Agencywide Documents Access and Management System (ADAMS). ADAMS is accessible from the NRC Website at http://www.nrc.qov/readinq | | Based on the results of this inspection, no findings of significance were identified. In accordance with 10 CFR 2.390 of the NRC's "Rules of Practice," a copy of this letter, its enclosure, and your response (if any) will be available electronically for public inspection in the NRC Public Document Room and from the Publicly Available Records (PARS) component of NRC's document system, Agencywide Documents Access and Management System (ADAMS). ADAMS is accessible from the NRC Website at http://www.nrc.qov/readinq-rm/adams.html (the Public Electronic Reading Room). |
| -rm/adams.html (the Public Electronic Reading Room). | |
|
| |
|
| Sincerely,/RA/ | | Sincerely, |
| Steven West, Director Division of Reactor Projects Docket No. 50 | | /RA/ |
| -255 License No. DPR | | Steven West, Director Division of Reactor Projects Docket No. 50-255 License No. DPR-20 |
| -20 | |
|
| |
|
| ===Enclosure:=== | | ===Enclosure:=== |
| Inspection Report 05000255/20110 12; w/Attachment s: 1. Supplemental Information 2. Memo to Jandovitz 3. Palisades Timeline cc w/encl: | | Inspection Report 05000255/20110 12; w/Attachment s: 1. Supplemental Information 2. Memo to Jandovitz 3. Palisades Timeline |
| Distribution via ListServ
| |
|
| |
|
| Enclosure U. S. NUCLEAR REGULATORY COMMISSION REGION I II Docket No.:
| | REGION I II Docket No.: |
| 50-255 License No.: | | 50-255 License No.: |
| DPR-20 Report No.: | | DPR-20 Report No.: |
Line 344: |
Line 337: |
| None | | None |
| ===Closed=== | | ===Closed=== |
| : None
| | None |
| ===Opened=== | | ===Opened=== |
| 05000 255/201 1 0 12-01 URI Adequacy of SW Pump Couplings | | 05000 255/201 1 0 12-01 URI Adequacy of SW Pump Couplings |
|
| |
|
| ==LIST OF DOCUMENTS REVIEWED== | | ==LIST OF DOCUMENTS REVIEWED== |
| ===Condition Reports===
| |
| : Title Date/Revision No.
| |
| : CR 04-02598 Root Cause Report for Perry Emergency Service Water Pump A Upper Shaft Coupling Sleeve Repeat Failure.
| |
| : CR 2011-03975 Relevant OE Not Considered in CR
| |
| -PLP-2009-4519 (Root Cause Evaluation for the 2009 Service Water Pump P-7C coupling Failure)
| |
| : August 12, 2011
| |
| : CR-PLP-2009-04519 Root Cause Evaluation Report for Service Water Pump P
| |
| -7C Failure to Provide Discharge Pressure March 4, 2009
| |
| : CR-PLP-2009-04542 Evaluate Early Station Response to Failure of P
| |
| -7C September 30, 2009
| |
| : CR-PLP-2009-04547 Inadequate FME Postings and Boundaries for Initial Disassembly of P
| |
| -7C September 30, 2009
| |
| : CR-PLP-2009-04561 Job Safety Hazard Analysis Not at Job Location for P
| |
| -7C September 30, 2009
| |
| : CR-PLP-2009-04571 Station in Event Response for Unexpected Loss of Service Water Pump P-7C September 30, 2009
| |
| : CR-PLP-2009-04593 Steps Not Followed Within WI
| |
| -SWS-M-04 for Reassembly of P
| |
| -7C October 1, 2009
| |
| : CR-PLP-2009-04613 Administrative Issues Involving Work Scheduling in Response to Emergent Equipment Issues October 2, 2009
| |
| : CR-PLP-2009-04616 Procedure Not In
| |
| -Hand for Packing Adjustments for P
| |
| -7C Pump Shaft October 2, 2009
| |
| : CR-PLP-2009-04659 Initial CR for CR
| |
| -PLP-2009-04806 October 6, 2009
| |
| : CR-PLP-2009-04806 Apparent Cause Evaluation to Evaluate Miscommunication of Independent Testing October 15, 2009
| |
| : CR-PLP-2009-04877 Service Water Pump P
| |
| -7C Exceeds Maintenance Rule Unavailability October 21, 2009
| |
| : CR-PLP-2009-05647 Documentation of HydroAire Root Cause Evaluation of Failed Line Shaft Coupling on P
| |
| -7C December 9, 2009
| |
| : CR-PLP-2009-05874 Evaluation of Past Operability Issues of
| |
| : P-7C Prior to the Event on 09/29/2009
| |
| : December 22, 2009
| |
| : CR-PLP-2010-01015 Error Identified in Licensee Event Report 2010
| |
| -001, Potential Loss of Safety Function Due to a Service Water Pump Shaft Coupling Failure March 10, 2010
| |
| : CR-PLP-2011-03902 Root Cause Report Service Water Pump 7-C Line Shaft Coupling Failure September 8, 2011
| |
| : CR-PLP-2011-03920 Non-covered Worker Has Exceeded Limits of EN
| |
| -FAP-OM-006 August 10, 2011
| |
| : CR-PLP-2011-03921 A-Frame Designated for Lifting P
| |
| -7C Service Water Pump Missing August 10, 2011
| |
| : CR-PLP-2011-03929 Non-Conforming Components Removed from P
| |
| -7C August 10, 2011
| |
| : CR-PLP-2011-03938 Outside Diameter Value and/or Tolerance in Error August 10, 2011
| |
| : CR-PLP-2011-03939 Degradation of Coating with Blisters on the Discharge Head of P
| |
| -7C August 10, 2011
| |
| : CR-PLP-2011-03942 Non-covered Worker Has Exceeded Limits of EN
| |
| -FAP-OM-006 August 11, 2011
| |
| : CR-PLP-2011-03944 Personnel Pulled from Training for Plant Event Response August 11, 2011
| |
| : CR-PLP-2011-03946 P-7C Work Temporarily Stopped Due to Non-Tethered Tools in FME Zone 1
| |
| : August 11, 2011
| |
| : CR-PLP-2011-03947 Hardhat Lost During P
| |
| -7C Disassembly August 11, 2011
| |
| : CR-PLP-2011-03948 Issues with Licensed Operator Training Identified August 11, 2011
| |
| : CR-PLP-2011-03952 Chlorination Deferment without Potential Adverse Effect August 11, 2011
| |
| : CR-PLP-2011-03959 Violation of Protected Equipment Boundary August 11, 2011
| |
| : CR-PLP-2011-03961 Potential Extent of Condition on Service Water Pumps P
| |
| -7A and P-7B August 11, 2011
| |
| : CR-PLP-2011-03963 Reverse Rotation Noticed of P
| |
| -7C During Breaker Opening August 11, 2011
| |
| : CR-PLP-2011-03965 Engineer Exceeds Overtime Limit August 11, 2011
| |
| : CR-PLP-2011-03966 Removed Couplings from P
| |
| -7C 2011 Failure Show Out
| |
| -of-Spec Hardness August 12, 2011
| |
| : CR-PLP-2011-03966 Results of 4 Couplings Sent to Consumers Energy Laboratory Services for Hardness Testing August 12, 2011
| |
| : CR-PLP-2011-03967 Service Water Pump P
| |
| -7C Lift Setting Not Validated Correctly August 12, 2011
| |
| : CR-PLP-2011-03967 Final Pump Lift Setting Not Validated Correctly August 11, 2011
| |
| : CR-PLP-2011-03968 Questioning of Pump Run in Dead Headed Condition August 11, 2011
| |
| : CR-PLP-2011-03975 Relevant OE not Considered in CR
| |
| -PLP-2009-04519 August 12, 2011
| |
| : LO-CAR-2009-00103 Nonconformance of Parts from HydroAire October 5, 2009
| |
| : LO-PLPLO-2009-00065 Implementation of Effectiveness Review Plan for RCE CR
| |
| -PLP-2009-04519 October 16, 2009
| |
| ===Documents===
| |
| : Title Date/Revision No.
| |
| : LER 2004-001-01 Emergency Service Water Pump Failure September 18, 2004
| |
| : Certificate of Conformance Certificate of Conformance for
| |
| : PO 10237148, Job# NQ5832
| |
| : June 9, 2009
| |
| : CP-PLP-2009-002 P-7C Service Water Pump Refurbishment Procurement Plan May 18, 2009
| |
| : EC 31208 Engineering Basis for Service Water Pump P-7C to be Considered Fully Operable Post
| |
| -Repair (August 2011 Coupling Failure)
| |
| : August 12, 2011
| |
| : EC 31218 Engineering Basis for Service Water Pump P-7A and P-7B to be Considered Operable Considering P
| |
| -7C Coupling Failure (August 2011 Coupling Failure)
| |
| : August 10, 2011
| |
| : Examination Report 00286627
| |
| : VT-2 (Pressure Test) of Service Water Pump P-7C Prior to Return to Service August 12, 2011
| |
| : HydroAire NDR
| |
| : Nonconformance and Discrepancy Report 09-55 October 2, 2009
| |
| : LO-WTHQN-2011-00439 Source Activity for Entergy Palisades PO10262979* Rev 000
| |
| : March 4, 2011
| |
| : LO-WTHQN-2011-00920 Source Activity for Entergy Palisades PO10262979, HydroAire Job No. NQ
| |
| : 5940 July 20, 2011
| |
| : MAT Project 0900609
| |
| : Consumers Energy Palisades Pump P7C Shaft Coupling Failure Analysis October 5, 2009
| |
| : NDR No. QANC
| |
| -09 97 HydroAire Nonconformance & Discrepancy Report and Part 21 Notification December 16, 2009
| |
| : NUPIC Audit Report VA11
| |
| -011 NUPIC Audit of HydroAire, Inc.
| |
| : June 1, 2011
| |
| : Purchase Order 10190242
| |
| : Procurement Documents for Pump P
| |
| -7A Couplings for 2009 Pump Refurbishment Revision 003
| |
| : Purchase Order 10237148
| |
| : Procurement Documents for Service Water Pump Refurbishment June 9, 2009
| |
| : Purchase Order 10246213
| |
| : Procurement Documents for Pump P
| |
| -7B Couplings for 2009 Pump Refurbishment Revision 004
| |
| : Purchase Order 10253715
| |
| : Procurement Documents for Pump P
| |
| -7C Couplings Following 2009 Coupling Failure Revision 003
| |
| : Report No. 1100112.401
| |
| : Structural Integrity Additional Review of Palisades Service Water Pump Couplings Revision 0
| |
| : Report PO 10324017
| |
| : Consumers Energy Rockwell Hardness Test Report for Couplings Removed from Failed Pump P
| |
| -7C August 10, 2011
| |
| : SQA2010-00131 HydroAire Source Surveillance Report SS010-016 March 16, 2010
| |
| : SQA2010-00561 HydroAire Source Surveillance Report SS010-158 November 2, 2010
| |
| : WO 00190235
| |
| : P-7C, Reduced Flow>RO
| |
| -144; Replace Pump Assembly per EC
| |
| -14577 June 10, 2009
| |
| : WO 00208591
| |
| : P-7C: Motor Shaft Broke. Repair Pump October 28, 2009
| |
| : WO 00209551
| |
| : RO-216 Service Water Pump Flow Verification September 15, 2010
| |
| : WO 00286627
| |
| : Test Spare P
| |
| -7C Motor IAW EN
| |
| -MA-134 Offline Motor Electrical Testing August 11, 2011
| |
| : WO 52211728
| |
| : P-7C IST Service Water Pump October 1, 2009
| |
| ===Procedures===
| |
| : Title Date/Revision No.
| |
| : ARP-7 Auxiliary Systems Scheme EK
| |
| -11 Revision 80
| |
| : BMS-WI 09.15.03
| |
| : Bodycote Heat Treatment of Martensitic Corrosion Resistant Steels Procedure July 10, 2006
| |
| : BMS-WI-09-00-02 Bodycote Determination of Heat Treat Process Time Procedure November 17, 2006
| |
| : EN-DC-115 Engineering Change Process Revision 11
| |
| : EN-DC-313 Procurement Engineering Process Revision 6
| |
| : EN-LI-102 Corrective Action Process Revision 16
| |
| : EN-LI-118 Root Cause Evaluation Process Revision 14
| |
| : EN-LI-118-01 Event & Causal Factor Charting Revision 0
| |
| : EN-LI-118-02 Change Analysis Revision 0
| |
| : EN-LI-118-03 Barrier Analysis Revision 0
| |
| : EN-LI-118-04 Task Analysis Revision 0
| |
| : EN-LI-118-05 Fault Tree Analysis Revision 0
| |
| : EN-LI-118-06 Common Cause Analysis Revision 1
| |
| : EN-LI-118-07 Behavioral Analysis Revision 0
| |
| : EN-LI-118-08 Failure Modes Analysis Revision 0
| |
| : EN-MA-118 Foreign Material Exclusion Revision 5
| |
| : EN-MP-100 Critical Procurements Revision 8
| |
| : EN-MP-101 Materials, Purchasing and Contracts Process Revision 5
| |
| : EN-MP-111 Inventory Control Revision 3
| |
| : EN-MP-117 Standardized Purchasing Process Revision 2
| |
| : EN-MP-120 Material Receipt Revision 4
| |
| : EN-MP-123 Term and Definitions Revision 4
| |
| : EN-MP-125 Control of Material Revision 7
| |
| : EN-QV-119 Corrective Action Requests, Supplier Stop Work Orders, and Recommendations Revision 7
| |
| : EN-QV-120 Planning, Performing, and Reporting Source Activities Revision 7
| |
| : EN-QV-121 Supplier Qualification/Maintenance of Qualifications Revision 5
| |
| : EN-QV-122 Qualified Suppliers List Revision 4
| |
| : EN-QV-123 Supplier Audits/Surveys Revision 4
| |
| : EN-WM-100 Work Request (WR) Generation, Screening and Classification Revision 6
| |
| ===Procedure===
| |
| : No QO
| |
| -14 Palisades Inservice Testing Procedure for Service Water Pumps May 25, 2011
| |
| ===Procedure===
| |
| : No RO
| |
| -144 Comprehensive Pump Test Procedure Service Water Pumps P
| |
| -7A, P-7B and P-7C Revision 4, (4/10/09)
| |
| ===Procedure===
| |
| : No.F11358
| |
| -P-001 LPI Procedure for Metallurgical Examination of SW Pump P
| |
| -7C Coupling Components August, 2011
| |
| : SOP-15 Service Water System Revision 51
| |
| : SOP-5 Containment Air Cooling Revision 28
| |
| : WI-MSM-M-26 Palisades Compression Fitting Installation and Inspection Revision 1
| |
| : WI-SWS-M-04 Service Water Pump P
| |
| -7B and P-7C Removal, Inspection, and Reinstallation Revision 7
| |
| ===Drawings===
| |
| : Title Date/Revision No.
| |
| : M0011-SH-0055 Palisades Service Water Pump Coupling Drawing.
| |
| : M-398 Level Setting Diagram Service Water and Dilution Water Pump Revision 2
| |
| : VEN-M11 Service Water Pump Rotating Element Assembly for Pumps P
| |
| -7A, 7B and 7C
| |
| : Revision 2
| |
| ==LIST OF ACRONYMS==
| |
| : [[USED]] [[]]
| |
| : [[ADAMS]] [[Agencywide Document Access Management System]]
| |
| : [[EC]] [[Engineering Change]]
| |
| : [[IGSCC]] [[Intergranular Stress Corrosion Cracking]]
| |
| : [[IMC]] [[Inspection Manual Chapter]]
| |
| : [[IP]] [[Inspection Procedure]]
| |
| : [[IR]] [[Inspection Report]]
| |
| : [[LCO]] [[Limiting Condition of Operation]]
| |
| : [[LPI]] [[Lucius Pitkin, Inc]]
| |
| : [[NRC]] [[]]
| |
| : [[U.S.]] [[Nuclear Regulatory Commission]]
| |
| : [[NUPIC]] [[Nuclear Procurement Issues Committee]]
| |
| : [[PARS]] [[Publicly Available Records System]]
| |
| QA Quality Assurance
| |
| Rc Rockwell C
| |
| : [[ROP]] [[Reactor Oversight Process]]
| |
| : [[RS]] [[Reactor Safety]]
| |
| : [[SBO]] [[Station Blackout]]
| |
| : [[SCAQ]] [[Significant Condition Adverse to Quality]]
| |
| : [[SI]] [[Structural Integrity]]
| |
| : [[SS]] [[Stainless Steel]]
| |
| : [[SW]] [[Service Water]]
| |
| : [[TS]] [[Technical Specification]]
| |
| : [[TSAC]] [[Technical Specification Action Statement]]
| |
| : [[URI]] [[Unresolved Item]]
| |
| : [[WR]] [[Work Request]]
| |
| : [[ATTACH]] [[MENT]]
| |
| : [[2 UNITED]] [[]]
| |
| : [[STATES]] [[NUCLEAR REGULATORY COMMISSION]]
| |
| : [[REGION]] [[]]
| |
| : [[III]] [[2443 WARRENVILLE ROAD,]]
| |
| : [[SUITE]] [[210]]
| |
| LISLE, IL 60532
| |
| -4352 Attachment
| |
| August 15, 2011 MEMORANDUM TO:
| |
| John Jandovitz, Project Engineer
| |
| Branch 5 Division of Reactor Projects
| |
| FROM: Steven West, Director
| |
| /RA/ Division of Reactor Projects
| |
| : [[SUBJEC]] [[T: SPECIAL INSPECTION CHARTER]]
| |
| : [[FOR]] [[]]
| |
| : [[PALISA]] [[DES NUCLEAR]]
| |
| : [[PLANT]] [[]]
| |
| FAILURE OF P
| |
| -7C
| |
| : [[SERVIC]] [[E]]
| |
| : [[WATER]] [[]]
| |
| : [[PUMP]] [[COUPLING]]
| |
| : [[ON]] [[]]
| |
| AUGUST 9, 2011
| |
| A potential repetitive failure of a coupling on the Palisades P
| |
| -7C service water pump was recently self
| |
| -revealed. The coupling failure is the subject of a Special Inspection that you have been identified to lead. A short discussion of the event follows.
| |
| On August 9, 2011, Palisades Nuclear Plant experienced a sudden loss of the P
| |
| -7C service water pump while it was in service. This failure resulted in the licensee entering a 72 hour Limiting Condition for Operation due to the inoperability of one service water train. The licensee disassembled the P
| |
| -7C pump and determined that the pump's first
| |
| line shaft to second line shaft coupling had failed. The licensee replaced all of the P
| |
| -7C pump's couplings and two portions of the pump shaft. After completing the required maintenance, the licensee returned pump P
| |
| -7C to service on August 12, 2011
| |
| Based upon our initial review, we are concerned that the licensee may not have taken effective corrective actions following a P
| |
| -7C service water pump coupling failure that occurred in September 2009. Following the September 2009 event, the licensee determined that the pump coupling failed due to improper heat treatment. The improper heat treatment resulted in the coupling's hardness being too high. The licensee's corrective actions included replacing the
| |
| P-7C SW pump's couplings with couplings of appropriate hardness. Recent hardness test
| |
|
| |
| J. Jandovicz
| |
| -2- results of several couplings removed from the P
| |
| -7C pump on August 10, 2011, indicate that these couplings were of an inappropriate hardness. Specifically, each coupling had at least one test location where the hardness measurement exceeded the licensee's acceptance criteria. In addition, one coupling had multiple test locations that exceeded the acceptance criteria. Testing of the failed coupling produced hardness results that were within specifications. Based upon the hardness test results and a March 2011 report provided to the licensee by Structural Integrity, another metallurgical failure mechanism may be contributing to the coupling failures. Lastly, this event raises questions about the effectiveness of the licensee's program for assessing and applying operating experience and its oversight of vendor activities.
| |
| The NRC has also learned that the remaining service water pumps, P
| |
| -7A and P-7B, have the same type of coupling installed. As a result, these pumps may also be susceptible to a coupling failure. The sequence of events and the root and contributing causes for this issue are being investigated by the licensee.
| |
| Based on the deterministic and risk
| |
| -based criteria in Management Directive 8.3, a Special Inspection at Palisades will commence on August 15, 2011. The Special Inspection Team, which is being led by you, will include Atif Shaikh. Other members may be assigned if specific
| |
| needs are identified.
| |
| The special inspection will determine the sequence of events, and will evaluate the facts, circumstances, and the licensee's actions surrounding this issue. The Special Inspection Charter for you and your team is enclosed.
| |
| Enclosure: As Stated
| |
| cc w/encl:
| |
| M. Satorius
| |
| C. Pederson
| |
| G. Shear S. Reynolds
| |
| : [[K.]] [[O'Brien]]
| |
| : [[D.]] [[Roberts,]]
| |
| : [[RI]] [[]]
| |
| : [[J.]] [[Clifford,]]
| |
| : [[RI]] [[]]
| |
| : [[P.]] [[Wilson,]]
| |
| : [[RI]] [[]]
| |
| : [[S.]] [[Weerakkody,]]
| |
| : [[RI]] [[]]
| |
| : [[R.]] [[Croteau,]]
| |
| : [[RII]] [[]]
| |
| : [[W.]] [[Jones,]]
| |
| : [[RII]] [[]]
| |
| : [[J.]] [[Munday,]]
| |
| : [[RII]] [[]]
| |
| : [[H.]] [[Christensen,]]
| |
| : [[RII]] [[]]
| |
| : [[K.]] [[Kennedy,]]
| |
| : [[RIV]] [[]]
| |
| : [[T.]] [[Pruett,]]
| |
| : [[RIV]] [[]]
| |
| : [[A.]] [[Vegel,]]
| |
| : [[RIV]] [[]]
| |
| : [[J.]] [[Lara,]]
| |
| RIII
| |
| V. Mitlying
| |
| : [[P.]] [[Chandrathil]]
| |
| : [[N.]] [[Valos D. Merzke A. Barker A. Shaikh RidsNrr]]
| |
| PMPalisadesResource
| |
| NRR Reactive
| |
| Inspection@nrc.gov
| |
|
| |
| J. Jandovitz
| |
| -2- The NRC has also learned that the remaining service water pumps, P
| |
| -7A and P-7B, have the same type of coupling installed. As a result, these pumps may also be susceptible to a coupling failure. The sequence of events and the root and contributing causes for this issue are being investigated by the licensee.
| |
| Based on the deterministic and risk
| |
| -based criteria in Management Directive 8.3, a Special Inspection at Palisades will commence on August 15, 2011. The Special Inspection Team, which is being led by you, will include Atif Shaikh. Other members may be assigned if specific
| |
| needs are identified.
| |
|
| |
| The special inspection will determine the sequence of events, and will evaluate the facts, circumstances, and the licensee's actions surrounding this issue. The Special Inspection Charter for you and your team is enclosed.
| |
|
| |
| Enclosure: As Stated
| |
| cc w/encl:
| |
| M. Satorius
| |
| C. Pederson
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| G. Shear S. Reynolds
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| : [[K.]] [[O'Brien]]
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| : [[D.]] [[Roberts,]]
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| : [[RI]] [[]]
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| : [[J.]] [[Clifford,]]
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| : [[RI]] [[]]
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| : [[P.]] [[Wilson,]]
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| : [[RI]] [[]]
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| : [[S.]] [[Weerakkody,]]
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| : [[RI]] [[]]
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| : [[R.]] [[Croteau,]]
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| : [[RII]] [[]]
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| : [[W.]] [[Jones,]]
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| : [[RII]] [[]]
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| : [[J.]] [[Munday,]]
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| : [[RII]] [[]]
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| : [[H.]] [[Christensen,]]
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| : [[RII]] [[]]
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| : [[K.]] [[Kennedy,]]
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| : [[RIV]] [[]]
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| : [[T.]] [[Pruett,]]
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| : [[RIV]] [[]]
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| : [[A.]] [[Vegel,]]
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| : [[RIV]] [[]]
| |
| : [[J.]] [[Lara,]]
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| RIII
| |
| V. Mitlying
| |
| : [[P.]] [[Chandrathil]]
| |
| : [[N.]] [[Valos D. Merzke A. Barker A. Shaikh RidsNrr]]
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| : [[PMP]] [[alisadesResource]]
| |
| : [[NRR]] [[Reactive Inspection@nrc.gov]]
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| DOCUMENT NAME:
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| G:\DRPIII\PALI\Palisades Special Inspection Charter for P7C coupling
| |
| failure.docx
| |
| See Previous Concurrence
| |
| Publicly Available
| |
| Non-Publicly Available
| |
| Sensitive Non-Sensitive To receive a copy of this document, indicate in the concurrence box "C" = Copy without attach/encl "E" = Copy with attach/encl "N" = No copy
| |
| : [[OFFICE]] [[]]
| |
| : [[RIII]] [[: RIII:]]
| |
| : [[NAME]] [[]]
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| KStoedter:dtp
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| : [[SW]] [[est]]
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| : [[DATE]] [[08/15/11 08/15/11]]
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| : [[OFFICI]] [[AL]]
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| : [[RECORD]] [[]]
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| COPY
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|
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|
| PALISADES SPECIAL INSPECTION CHARTER
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| This Special Inspection Team is chartered to assess the circumstances surrounding the failure of a coupling on the P
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| -7C service water pump on August 9, 2011. The Special Inspection will be conducted in accordance with Inspection Procedure 93812, "Special Inspection." The
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| special inspection will include, but not be limited to, the items listed below. This charter may be revised based on the results and findings of the inspection.
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| 1. Establish a historical sequence of events related to service water pump coupling failures up to and including the most recent failure on August 9, 2011.
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| 2. In light of the failure of the P
| |
| -7C service water pump, review the licensee's basis for operability of the P
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| -7A, P-7B, and P-7C service water pumps. Determine whether the licensee has an adequately supported basis for operability of the P
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| -7A and P-7B pumps and for returning the P-7C pump to service. Determine if additional corrective actions are required. 3. Evaluate activities associated with the licensee's repair of the P
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| -7C pump for adequacy. Confirm that the repair complies with licensee and NRC requirements.
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| 4. Review information and processes relied upon by Palisades to determine whether or not critical attributes of service water pump line shaft couplings, such as hardness, are
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| acceptable prior to coupling installation.
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| 5. Evaluate the licensee's procedures and processes for evaluating/assessing the performance of vendors. Emphasis should be placed upon determining why couplings
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| that were believed to be of an appropriate hardness were later found to be of an inappropriate hardness. Review any evaluations/assessments of HydroAire that were completed by the licensee following the September 2009 P
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| -7C coupling failure. Also, review any actions taken or direction provided by the licensee to HydroAire in response to the recent hardness test results.
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| 6. Evaluate the licensee's operating experience program with
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| an emphasis on operating experience related to
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| pump components manufactured by Hyrdo
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| -Aire. Specific attention should be given to the licensee's evaluation of a 2010 service water pump coupling failure at Prairie Island and the evaluation of a March 2011 report from Structural Integrity regarding the potential for coupling failure due to temper embrittlement.
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| Review the licensee's root cause evaluation plan and schedule. Include the schedule for
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| performing testing of any components removed from the P
| |
| -7C pump. Evaluate whether the root cause evaluation plan is of sufficient depth and breadth. Confirm that the time allowed to perform the root cause evaluation is commensurate with the safety significance of this issue. Communicate to the licensee that the NRC will inspect the completed root cause evaluation and
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| the associated corrective actions as part of our normal inspection activities.
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|
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| Additional Inspection Requirements
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| 1. Determine if there are any lessons learned from this Special Inspection.
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| Charter Approval
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| /RA by Karla Stoedter for/
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| 8/15/11 John Giessner, Chief
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| Branch 4 Division of Reactor Projects
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| _________/RA/_ 8/15/11_______
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| Steven West, Director
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| Division of Reactor Projects
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|
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| ATTACHMENT 3
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| Palisades P
| |
| -7C Service Water Pump Timeline
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| September 12, 1991
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| Beaver Valley Unit 1 experiences a coupling failure of a Byron
| |
| -Jackson centrifugal pump as a result of embrittlement of
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| : [[410 SST]] [[due to improper tempering temperatures and potential impurities. The failure mechanism was]]
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| IGSCC.
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| September 1, 1993
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| NRC Information Notice 93
| |
| -68, "Failure of Pump Shaft Coupling Caused by Temper Embrittlement During Manufacture" is issued informing
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| licensees of problems stemming from temper embrittlement of 410 SS supplied by Byron
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| -Jackson (referring to the 1991 Beaver Valley event).
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| September 22, 1993
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| Indian Point Unit 2 experiences a pump failure via a failed coupling attributed to a non
| |
| -ductile fracture because of temper embrittlement of the
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| : [[410 SST]] [[used. The failure mechanism was]]
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| IGSCC.
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| September 1, 2003
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| Perry Unit 1 experienced a coupling disassembly event on their Emergency Service Water 'A' pump. The failure mechanism was by IGSCC and no performance effects were
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| noticed before the failure of the coupling. The shafts were 416SS.
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| May 21, 2004 Perry experiences additional failure s of Emergency Service Water pump
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| shafts composed of
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| : [[416 SS.]] [[The failure mechanism was by]]
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| IGSCC
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| . 2006 INPO Operating Experience Digest 2006
| |
| -02 - INPO releases a document that discusses service water pump (shaft, coupling and impeller) failures
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| occurring in the industry. The report notes that 12 failures occurred between 1998 and 2006 with the most frequent including corrosion causing coupling separation. One of the common causes identified was
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| improper heat treatment of the material during manufacturing.
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| February 9, 2007
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| NRC Information Notice 2007
| |
| -05, "Vertical Deep Draft Pump Shaft and Coupling Failures" is issued that references the coupling failures from
| |
| : [[IGSCC]] [[that occurred at Columbia Generating Station. The couplings were]]
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| TP410 martensitic stainless steel and were susceptible to tempering embrittlement. The operating experience review identified
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| at least 23 essential SW pump shaft and coupling failures since 1983 involving more than six different manufacturers.
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| December ,
| |
| : [[2007 EC]] [[-5000121762 was initiated to change the]]
| |
| : [[SW]] [[pump internal components, in including the shaft couplings, from carbon steel to 416]]
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| SS.
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| April 4, 2009
| |
| P-7A couplings and shaft
| |
| s were changed to
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| : [[416 SS]] [[from carbon steel under]]
| |
| WO 51637416 (Heat Number 49293)
| |
|
| |
| April 10, 2009
| |
| P-7C fails Technical Specification Surveillance Test RO
| |
| -144 , "Comprehensive Pump Test Procedure Service Water Pumps P
| |
| -7A, P-7B and P-7C ," via a low flow condition and the pump is declared inoperable
| |
| (test performed during refueling outage)
| |
| April 25, 2009
| |
| P-7C declared Operable with Compensatory Measures due to Op Eval showing that P
| |
| -7C would demonstrate its 30 day mission time with degraded flow prior to startup from outage
| |
| May 19, 2009
| |
| Purchase Order #10237148 issued to HydroAire to re
| |
| -build Layne and Bowler pump to replace P
| |
| -7C May 21-22, 2009 Pump P-7C couplings were
| |
| heat treated once and then received a second heat treatment.
| |
| June 12, 2009
| |
| P-7C couplings and shaft changed to
| |
| : [[416 SS]] [[from carbon steel under]]
| |
| WO 190235 September 29, 2009
| |
| P-7C pump failed due to coupling #7 failure from IGSCC. The pump had a total run time of 2414.44 hours with 13 starts/stops.
| |
|
| |
| October 1, 2009
| |
| First two couplings from HydroAire arrive (Heat Order #20163) early. Remaining six couplings arrive later in day (Heat Order #20166) and installed.
| |
| October 2, 2009
| |
| P-7C restored to operation
| |
| May 13, 201
| |
| P-7B couplings and shaft changed to
| |
| : [[416 SS]] [[from carbon steel under]]
| |
| WO 213444 (Heat
| |
| Number W2464-B50) July, 2010
| |
| Prairie Island experience
| |
| d a failure of
| |
| : [[0 SS]] [[couplings from]]
| |
| : [[IGSCC.]] [[These couplings were also supplied by HydroAire. March, 2011 Structural Integrity (SI) report received at Palisades concerning failure mechanisms of]]
| |
| : [[416 SS]] [[. August, 2011]]
| |
| SI report accepted
| |
| by Licensee.
| |
|
| |
| August 9, 2011
| |
|
| |
| 0700 All 3 SW pumps in
| |
| -service with differential pressures of 1/2/1 psid, respectively and header pressure is 73 psig and stable. P-7C operated for a total of
| |
| ,114.86 hours with a total of 95 starts/stops and had passed all surveillances
| |
|
| |
| 202 Control room receives following alarms:
| |
| : [[EK]] [[-1163 "Critical Service Water Header 'B']]
| |
| : [[LO]] [[Pressure;"]]
| |
| : [[EK]] [[-1164 "Critical Service Water Header 'A']]
| |
| : [[LO]] [[Pressure;"]]
| |
| : [[EK]] [[-1165 "Non-Critical Service Water]]
| |
| LO Press;" EK
| |
| -0557 "Diesel Gen No. 1
| |
| -2 Trouble;" and
| |
| : [[EK]] [[-1132 "Service Water Pump P7A Basket]]
| |
| : [[STR]] [[]]
| |
| : [[HI]] [[]]
| |
| : [[DP.]] [[Operators enter Off Normal Procedure 6.1 for Loss of Service Water and enter]]
| |
| : [[TS]] [[]]
| |
| LCO 3.7.8.A1 (restore SW pump P
| |
| -7C to operable in 72 hours)
| |
| 203 Nuclear Plant Operator reports that P
| |
| -7C has no discharge pressure and a loud banging noise from the pump. Operators stop pump P
| |
| -7C. Header pressure is
| |
| stable at 64 psig. All alarms except EK
| |
| -1132 clear.
| |
| 246 CR-PLP-2011-03902 created to document failure of P
| |
| -7C and initiates root cause investigation and identified as significant condition adverse to quality 1303 Operators exit ONP 6.1
| |
|
| |
| 1530 BS-1320 completed identifying only zebra mussel shells in strainer
| |
| August 10, 2011
| |
|
| |
| 0107 P-7C motor and pump uncoupled
| |
|
| |
| 215 P-7C motor removed
| |
|
| |
| 25 All P-7C shafts removed. P-7C pump failed due to coupling #6 failure.
| |
| August 10, 2011 Jackson Labs independently performs hardness tests on 4 couplings and identifies
| |
| that three couplings have at least one hardness value out
| |
| -of-specification
| |
| high. August 11, 2011
| |
| 0135 P-7C shaft reassembly commence
| |
| d with couplings from Traveler 27797 (Heat Order 20170)
| |
| .
| |
| 1059 P-7C pump reassembly complete
| |
| d. 1215 P-7C motor reinstallation completed
| |
| .
| |
| August 12, 2011
| |
| P-7C declared Operable after completion of Post Maintenance Testing
| |
| (WO 286627)
| |
| and return-to-service Surveillance Testing (WO 286774)
| |
| . August 16-17, 2011 All P-7C couplings sent to Lucius Pitkin Inc (LPI). Metallurgical plan is still in draft form.
| |
| }} | | }} |
|
---|
Category:Inspection Report
MONTHYEARIR 05000255/20244022024-09-0606 September 2024 Public: Palisades Nuclear Plant - Decommissioning Security Inspection Report 05000255/2024402 IR 05000255/20240022024-08-0909 August 2024 NRC Inspection Report No. 05000255/2024002 IR 05000255/20240112024-07-15015 July 2024 Nuclear Plant - Restart Inspection Report 05000255/2024011 IR 05000255/20240012024-05-10010 May 2024 NRC Inspection Report No. 05000255/2024001 IR 05000255/20244012024-04-0909 April 2024 – Decommissioning Security Inspection Report 05000255/2024401 IR 05000255/20240102024-03-20020 March 2024 Plant Reference Simulator Inspection Report 05000255/2024010 IR 05000255/20230042024-02-20020 February 2024 NRC Inspection Report 05000255/2023004(DRSS) Holtec Decommissioning International, LLC, Palisades Nuclear Plant IR 05000255/20230032023-10-0404 October 2023 NRC Inspection Report No. 05000255/2023003(DRSS)-Holtec Decommissioning International, LLC, Palisades Nuclear Plant IR 05000255/20230022023-07-19019 July 2023 NRC Inspection Report 05000255/2023002 DRSS-Holtec Decommissioning International, LLC, Palisades Nuclear Plant IR 05000255/20220032022-12-28028 December 2022 NRC Inspection Report No. 05000255/2022003(DRSS); 07200007/2022001 (Drss) Holtec Decommissioning International, LLC, Palisades Nuclear Plant IR 05000255/20224012022-11-0909 November 2022 Decommissioning Palisades Nuclear Plant - Decommissioning Security Inspection Report 05000255/2022401 IR 05000255/20220022022-08-0303 August 2022 Integrated Inspection Report 05000255/2022002 IR 05000255/20220012022-05-13013 May 2022 Integrated Inspection Report 05000255/2022001 IR 05000255/20220102022-04-0101 April 2022 Triennial Inspection of Evaluation of Changes, Tests and Experiments Baseline Inspection Report 05000255/2022010 IR 05000255/20210062022-03-0202 March 2022 Annual Assessment Letter for Palisades Nuclear Plant, Unit 1, (Report 05000255/2021006) IR 05000255/20210102022-02-24024 February 2022 Triennial Fire Protection Inspection Report 05000255/2021010 IR 05000255/20210042022-02-0808 February 2022 Integrated Inspection Report 05000255/2021004 and Exercise of Enforcement Discretion IR 05000255/20214042021-11-15015 November 2021 NRC Independent Spent Fuel Storage Installation Security Inspection Report 05000255/2021404 and 07200007/2021401 IR 05000255/20210032021-11-0303 November 2021 Integrated Inspection Report 05000255/2021003 IR 05000255/20214032021-10-21021 October 2021 Material Control and Accounting Program Inspection Report 05000255/2021403 IR 05000255/20214022021-10-0606 October 2021 Security Baseline Inspection Report 05000255/2021402 IR 05000255/20210052021-09-0101 September 2021 Updated Inspection Plan for Palisades Nuclear Plant (Report 05000255/2021005) IR 05000255/20210022021-08-10010 August 2021 Integrated Inspection Report 05000255/2021002 ML21197A0322021-07-21021 July 2021 Review of the Fall 2020 Steam Generator Tube Inspection Report IR 05000255/20210012021-05-12012 May 2021 Integrated Inspection Report 05000255/2021001 IR 05000255/20214012021-04-14014 April 2021 Security Baseline Inspection Report 05000255/2021401 IR 05000255/20200062021-03-0404 March 2021 Annual Assessment Letter for Palisades Nuclear Plant (Report 05000255/2020006) IR 05000255/20200042021-02-11011 February 2021 Integrated Inspection Report 05000255/2020004 IR 05000255/20204012021-01-0606 January 2021 Security Baseline Inspection Report 05000255/2020401 ML20342A1812020-12-10010 December 2020 Security Inspection Report Cover Letter 05000255/2020420 IR 05000255/20204202020-12-10010 December 2020 Security Inspection Report 05000255/2020420 IR 05000255/20204022020-11-30030 November 2020 Cyber Security Inspection Report 05000255/2020402 IR 05000255/20205012020-11-20020 November 2020 Emergency Preparedness Inspection Report 05000255/2020501 IR 05000255/20200032020-11-13013 November 2020 Integrated Inspection Report 05000255/2020003 IR 05000255/20200052020-09-0101 September 2020 Updated Inspection Plan for Palisades Nuclear Plant (Report 05000255/2020005) IR 05000255/20200102020-08-24024 August 2020 Biennial Problem Identification and Resolution Inspection Report 05000255/2020010 IR 05000255/20203012020-08-13013 August 2020 NRC Initial License Examination Report 05000255/2020301 IR 05000255/20200022020-08-11011 August 2020 Integrated Inspection Report 05000255/2020002 and Exercise of Enforcement Discretion IR 05000255/20010082020-05-12012 May 2020 Final ASP Analysis - Palisades (IR 050002552001008) IR 05000255/20200012020-05-12012 May 2020 Integrated Inspection Report 05000255/2020001 IR 05000255/20200112020-04-21021 April 2020 Design Basis Assurance Inspection (Teams) Inspection Report 05000255/2020011 IR 05000254/20204012020-03-23023 March 2020 Security Baseline Inspection Report 05000254/2020401 and 05000265/2020401 IR 05000255/20190062020-03-0303 March 2020 Annual Assessment Letter Palisades Nuclear Plant (Report 05000255/2019006) IR 05000255/20190042020-01-28028 January 2020 Integrated Inspection Report 05000255/2019004 and 07200007/2019001 ML19357A2752019-12-23023 December 2019 Request for Information for an NRC Triennial Baseline Design Bases Assurance Inspection (Team); Inspection Report 05000255/2020011 IR 05000255/20190112019-11-27027 November 2019 Triennial Inspection of Evaluation of Changes, Tests and Experiments Baseline Inspection Report 05000255/2019011 IR 05000255/20194112019-11-25025 November 2019 Security Baseline Inspection Report 05000255/2019411 and Independent Spent Fuel Storage Security Inspection Report 07200007/2019401 (Cover Letter Only) (DRS-M.Ziolkowski) IR 05000255/20190032019-11-14014 November 2019 Integrated Inspection Report 05000255/2019003 IR 05000255/20190102019-10-29029 October 2019 Reissue - Palisades Nuclear Plant - Design Basis Assurance Inspection (Programs) Inspection Report 05000255/2019010 ML19294A2872019-10-21021 October 2019 Design Basis Assurance Inspection (Programs) Inspection Report 05000255/2019010 2024-09-06
[Table view] Category:Letter
MONTHYEARPNP 2024-014, Request for USNRC to Rescind Approved Exemption Requests for 140.11(a)(4) and 50.54(w)(1), Reduction of Insurances2024-10-0909 October 2024 Request for USNRC to Rescind Approved Exemption Requests for 140.11(a)(4) and 50.54(w)(1), Reduction of Insurances PNP 2024-037, Response to Requests for Additional Information Regarding the Proposed Reauthorization of Power Operations Under Renewed Facility Operating License Number DPR-0202024-10-0404 October 2024 Response to Requests for Additional Information Regarding the Proposed Reauthorization of Power Operations Under Renewed Facility Operating License Number DPR-020 ML24267A2962024-10-0101 October 2024 Summary of Conference Call Regarding Steam Generator Tube Inspections ML24263A1712024-09-20020 September 2024 Environmental Request for Additional Information ML24240A1692024-09-18018 September 2024 Cy 2023 Summary of Decommissioning Trust Fund Status ML24219A4202024-09-12012 September 2024 Change in Estimated Hours and Review Schedule for Licensing Actions Submitted to Support Resumption of Power Operations (Epids L-2023-LLE-0025, L-2023-LLM-0005, L-2023-LLA-0174, L-2024-LLA-0013, L-2024-LLA-0060, L-2024-LLA-0071) IR 05000255/20244022024-09-0606 September 2024 Public: Palisades Nuclear Plant - Decommissioning Security Inspection Report 05000255/2024402 PNP 2024-029, Notice of Payroll Transition at Palisades Nuclear Plant2024-08-15015 August 2024 Notice of Payroll Transition at Palisades Nuclear Plant IR 05000255/20240022024-08-0909 August 2024 NRC Inspection Report No. 05000255/2024002 PNP 2024-030, Update Report for Holtec Decommissioning International Fleet Decommissioning Quality Assurance Program Rev. 3 and Palisades Transitioning Quality Assurance Plan, Rev 02024-08-0202 August 2024 Update Report for Holtec Decommissioning International Fleet Decommissioning Quality Assurance Program Rev. 3 and Palisades Transitioning Quality Assurance Plan, Rev 0 PNP 2024-032, Supplement to License Amendment Request to Revise Selected Permanently Defueled Technical Specifications Administrative Controls to Support Resumption of Power Operations2024-07-31031 July 2024 Supplement to License Amendment Request to Revise Selected Permanently Defueled Technical Specifications Administrative Controls to Support Resumption of Power Operations ML24206A0572024-07-25025 July 2024 PRM-50-125 - Letter to Alan Blind; Docketing of Petition for Rulemaking and Sufficiency Review Status (10 CFR Part 50) PNP 2024-033, Response to Request for Additional Information - License Amendment Request to Revise the Palisades Nuclear Plant Site Emergency Plan to Support Resumption of Power Operations2024-07-24024 July 2024 Response to Request for Additional Information - License Amendment Request to Revise the Palisades Nuclear Plant Site Emergency Plan to Support Resumption of Power Operations PNP 2024-031, Response to RIS 2024-01, Preparation and Scheduling of Operator Licensing Examinations2024-07-18018 July 2024 Response to RIS 2024-01, Preparation and Scheduling of Operator Licensing Examinations IR 05000255/20240112024-07-15015 July 2024 Nuclear Plant - Restart Inspection Report 05000255/2024011 PNP 2024-027, Supplement to License Amendment Request to Revise Renewed Facility Operating License and Permanently Defueled Technical Specifications to Support Resumption of Power Operations2024-07-0909 July 2024 Supplement to License Amendment Request to Revise Renewed Facility Operating License and Permanently Defueled Technical Specifications to Support Resumption of Power Operations ML24183A1382024-07-0202 July 2024 Tribal Letter - Lac Du Flambeau Band of Lake Superior Chippewa Indians ML24137A0142024-07-0202 July 2024 OEDO-24-00011 - 2.206 Petition for Misuse of Palisades Decommissioning Trust Fund (EPID L-2023-CRS-0008) - Letter ML24183A1492024-07-0101 July 2024 Tribal Letter - Pokagon Band of Potawatomi Indians ML24156A0222024-07-0101 July 2024 Initiation of Scoping Process to Prepare an Environmental Assessment for the Environmental Review of Holtec Decommissioning International, Llc’S Licensing and Regulatory Requests for Reauthorization of Power Operations at Palisades EPID L-2 ML24183A1552024-07-0101 July 2024 Tribal Letter - Red Lake Band of Chippewa Indians ML24183A1542024-07-0101 July 2024 Tribal Letter Red Cliff Band of Lake Superior Chippewa Indians ML24172A0032024-07-0101 July 2024 Letter to L. Powers, Mackinac Bands of Chippewa and Ottawa Indians Re Initiation of Scoping Process for Environ Review Holtec Decommissioning Intl, LLC Request for Reauthorization of Power Ops-Palisades ML24183A1332024-07-0101 July 2024 Tribal Letter-Forest County Potawatomi Community ML24183A1582024-07-0101 July 2024 Tribal Letter Sault Ste. Marie Tribe of Chippewa Indians ML24183A1302024-07-0101 July 2024 Tribal Letter-Chippewa Cree Indians of the Rocky Boys Reservation ML24183A1282024-07-0101 July 2024 Tribal letter-Bay Mills Indian Community ML24183A1532024-07-0101 July 2024 Tribal Letter Quechan Tribe of the Fort Yuma Indian Reservation ML24183A1572024-07-0101 July 2024 Tribal Letter - Saint Croix Chippewa Indians of Wisconsin ML24183A1462024-07-0101 July 2024 Tribal letter-Mille Lacs Band of Ojibwe ML24183A1422024-07-0101 July 2024 Tribal Letter-Little Traverse Bay Bands of Odawa Indians ML24183A1312024-07-0101 July 2024 Tribal Letter-Citizen Potawatomi Nation ML24163A0552024-07-0101 July 2024 Rebecca Held Knoche NOAA-Palisades-NOI to Conduct Scoping Process and Prepare an EA - EPID No. L-2024-LNE-0003-Docket No. 50-0255 ML24163A2392024-07-0101 July 2024 Sara Thompson, Michigan DNR-Palisades-NOI to Conduct Scoping Process and Prepare an EPID No. L-2024-LNE-0003-Docket No. 50-0255 ML24155A0102024-07-0101 July 2024 Quentin L. Messer Jr., Michigan Econ-Palisades-NOI to Conduct Scoping Process and Prep an EA-EPID No. L-2024-LNE-0003 Docket No.50-0255P ML24155A0032024-07-0101 July 2024 Kathy Kowal, Us EPA Region 5-Palisades-NOI to Cibdyct Scoping Process and Prepare an EA EPID L-2024-LNE-0003 ML24163A0832024-07-0101 July 2024 Ltr to R Schumaker SHPO Re Initiation of Scoping Process, Section 106 Consult for Env Rev of HDI, LLC Request for Reauth of Power Operations at Palisades Nuclear Plant ML24183A1342024-07-0101 July 2024 Tribal Letter-Grand Portage Band of Lake Superior Chippewa ML24183A1392024-07-0101 July 2024 Tribal Letter-Lac Vieux Desert Band of Lake Superior Chippewa Indians ML24183A1272024-07-0101 July 2024 Tribal Letter-Bad River Band of the Lake Superior Tribe of Chippewa ML24183A1412024-07-0101 July 2024 Tribal Letter-Little River Band of Ottawa Indians ML24163A1922024-07-0101 July 2024 Jeremy Rubio, Dept of Env, Great Lakes and Energy, Kalamazoo District-Palisades-NOI to Conduct Scoping Process and Prepare an EA EPID No. L-2024-LNE-0003 Docket No.50-0255 ML24183A1322024-07-0101 July 2024 Tribal Letter-Fond Du Lac Band of Lake Superior Chippewa ML24183A1592024-07-0101 July 2024 Tribal letter-Sokaogon Chippewa Community ML24163A0822024-07-0101 July 2024 Ltr to J Loichinger Achp Re Initiation of Scoping Process, Section 106 Consult for Env Rev of HDI, LLC Request for Reauth of Power Operations at Palisades Nuclear Plant ML24183A1252024-07-0101 July 2024 Letter to G. Gould, Swan Creek Black River Confederated Ojibwa-Init of Scoping Process for the Env Rev of Holtec Decommissioning Intl, LLC Request for Reauth of Power Ops at Palisades ML24183A1352024-07-0101 July 2024 Tribal Letter-Hannahville Indian Community ML24183A1442024-07-0101 July 2024 Tribal Letter - Menominee Indian Tribe of Wisconsin ML24183A1502024-07-0101 July 2024 Tribal Letter - Prarie Band Potawatomi Nation ML24183A1452024-07-0101 July 2024 Tribal Letter - Miami Tribe of Oklahoma 2024-09-06
[Table view] |
Text
October 4, 2011
SUBJECT:
PALISADES NUCLEAR PLANT
- NRC SPECIAL INSPECTION TEAM (SIT) REPORT 05000255/2011012
Dear Mr. Vitale:
On September 1, 2011, the United States Nuclear Regulatory Commission (NRC) completed a special inspection at your Palisades Nuclear Plant. The inspection was conducted in response to the circumstances surrounding the failure of the Service Water Pump P-7C, on August 9, 2011. Based on the risk and deterministic criteria specified in Management Directive 8.3, "NRC Incident Investigation Program," a special inspection was initiated in accordance with Inspection Procedure 93812, "Special Inspection."
The special inspection charter (Attachment 2 of the enclosure) provides the basis and focus areas for the inspection.
The enclosed inspection report documents the inspection results, which were discussed with you and other members of your staff at the exit meeting on September 1, 2011.
The determination that the special inspection would be conducted was made on August 15, 2011, and the on-site inspection commenced the same day.
The inspection examined activities conducted under your license as they relate to safety, compliance with the Commission's rules and regulations, and with the conditions of your license. The inspectors reviewed selected procedures and records, conducted field walkdowns, and interviewed personnel.
Based on the results of this inspection, no findings of significance were identified. In accordance with 10 CFR 2.390 of the NRC's "Rules of Practice," a copy of this letter, its enclosure, and your response (if any) will be available electronically for public inspection in the NRC Public Document Room and from the Publicly Available Records (PARS) component of NRC's document system, Agencywide Documents Access and Management System (ADAMS). ADAMS is accessible from the NRC Website at http://www.nrc.qov/readinq-rm/adams.html (the Public Electronic Reading Room).
Sincerely,
/RA/
Steven West, Director Division of Reactor Projects Docket No. 50-255 License No. DPR-20
Enclosure:
Inspection Report 05000255/20110 12; w/Attachment s: 1. Supplemental Information 2. Memo to Jandovitz 3. Palisades Timeline
REGION I II Docket No.:
50-255 License No.:
DPR-20 Report No.:
05000 255/201 1 0 12 Licensee:
Entergy Nuclear Operations, Inc.
Facility:
Palisades Nuclear Plant Location:
Covert, MI Dates: August 15, 201 1 - September 1, 201 1 Inspectors
- J. Jandovitz , Project Engineer (Lead) A. Shaikh, Reactor Inspector P. Smagacz, Reactor Engineer Approved by:
John B. Giessner, Chief Branch 4 Division of Reactor Projects
Enclosure
SUMMARY OF FINDINGS
IR 05000 255/20 10 012; 08/15/20 1 1 09/01/20 1 1; Palisades Nuclear Plant;
Inspection Procedure 93812, Special Inspection
. This report covers a 4
-day period (August 15
-19 , 20 1 1) of on-site inspection and in-office review through September 1, 2011. A team, comprised of three regional inspectors, conducted this special inspection.
The NRC's program for overseeing the safe operation of commercial nuclear power reactors is described in NUREG
-1649, "Reactor Oversight Process," Revision 4, dated December 2006.
A. No findings were identified.
NRC-Identified and Self-Revealing Findings
B. No findings were identified.
=
Licensee-Identified Violations===
REPORT DETAILS
At 12:02 p.m. EDT on August 9, 2011, the licensee entered an unplanned 72
-hour shutdown Technical Specification limiting condition for operation (LCO) action statement (TSAC)due to failure of service water (SW) pump P-7C. The SW system includes three mot or-driven , vertical multistage deep draft pumps that provide cooling water to safety related equipment (component cooling water, containment air coolers, diesel generators, control room coolers, etc.). Each pump has 50 percent capacity
- and two pumps are required to be in service
- however, the technical specification requires all three pumps to be operable.
All three pumps were running prior to the failure. Summary of the Degrade d Condition The licensee observed a low differential pressure condition and low pump amperage following the failure of the pump. The licensee disassembled pump P-7C and determined that the pump's first line shaft to second line shaft coupling, #6, had failed. The licensee replaced all of the pump P-7C couplings and two portions of the pump shaft. After completing the required maintenance and surveillance tests, the licensee returned pump P
-7C to service on August 12 , within the time allowed by the TSAC. Pump P-7C had previously experienced another coupling failure in September 2009. The SW pump couplings in both cases were made of 416 Stainless Steel. Subsequent metallurgical analysis determined the coupling's hardness was significantly higher than the design specification; and the failure was caused by Intergranular Stress Corrosion Cracking (IGSCC)
. The licensee's corrective actions in 2009 included replacing all the SW pump P-7C couplings with couplings of the same design and hardness criteria
. However, hardness test results of several couplings removed from pump P-7C on August 10, 2011, indicate d that these couplings were not within the hardness specification. Specifically, three of the couplings had at least one test location where the hardness measurement w as higher than the licensee's design specification criteria. Based on the deterministic and conditional risk criteria specified in Management Directive 8.3, "NRC Incident Investigation Program," a special inspection was initiated in accordance with NRC Inspection Procedure 93812, "Special Inspection Team." The special inspection charter, dated August 15, 2011, is included as Attachment 2. The team reviewed technical and design documents, procedures, maintenance records, and corrective action documents
- interviewed station personnel and consultants
- and performed plant walkdowns of plant equipment. A list of specific documents reviewed is provided in Attachment 1.
Inspection Scope
4OA5 Other Activities
- Special InspectionIn accordance with the Charter, the following items were reviewed.
(93812)
.1 Establish a historical sequence of events related to service water pump coupling failures up to and including the most recent failure on August 9, 2011
a. . The inspectors reviewed corrective action documents, operating experience reports, technical literature, operation history, surveillance procedures and results, vendor procurement and manufacturing records, and interviewed plant personnel for information related to the use of 416 Stainless Steel (SS) material, and similar material such as 410SS, in power plant applications, particularly, SW pumps. Inspection Scope A detailed historical timeline of activities and information involving use and experience is contained in Attachment 3. b. No findings were identified.
Findings and Observations The inspectors were concerned that the licensee had not adequately evaluate d operating experience to recognize the vulnerabilities of 416SS material to IGSCC based on material properties, particularly heat treatment. This concern is di scussed further in the unresolved item (URI) in Section
.0 7 of this report.
However, the inspectors did not identify any operational or surveillance results or observations that may have predicted the failure of SW pump P-7 C on August 9, 2011.
.2 Review the licensee's basis for operability of the service water pumps
P-7A, P-7B, and P-7C. Determine whether the licensee ha d an adequately supported basis for operability of pumps P-7A and P-7B and for returning pump P-7C to service. Determine if additional corrective actions are required a. . The inspectors reviewed the prompt operability basis for all three SW pumps contained in Engineering Change (EC) 31208 and EC 31218. The inspectors identified run times, service conditions and life, starts and stops, heats of materials, and differences in heat treatment for the in-service couplings.
Inspection Scope b. No finding s were identified
. Findings and Observations Based on th e information available, the inspectors did not disagree with the immediate or prompt operability evaluation s. The prompt operability for SW pumps P-7B and P-7C w as based on the higher confidence that the hardness of the couplings installed in the pumps were within the design specification range, and therefore less susceptible to IGSCC. Operability for pump P-7A was based on the fact that couplings installed in th at pump had been in operation the longest with no failures.
However, the inspectors noted that there was no discussion on temper embrittlement identified in the Structural Integrity (SI)report and in operating experience, as a factor that may affect the coupling s' reliability. Therefore, it was recognized that the results from the metallurgy and root cause evaluation may impact the basis for current operability and the couplings
' service life.
After the on
-site SIT inspection was complete, the licensee received initial metallurgical results on the failed coupling and initiated a near-term replacement plan of the couplings in all three SW pumps with couplings of a different material, more resistant to IGSCC.
At the time of the SIT exit, the couplings in pump P
-7A had been replaced with the new material. The NRC will continue to monitor results from the root cause investigation for impact on the operability basis for any pump that still has the 416SS couplings.
The residents will also evaluate the licensee's evaluation of past operability for all the SW pumps and the extent of condition evaluation for the 416SS components remaining in the pumps
.
.3 Evaluate activities associated with the licensee's repair of service water pump P-7C for adequacy.
Confirm that the repair complies with licensee and NRC requirements a. . The inspectors reviewed the licensee's repair and replacement activities associated with the rebuild of pump P
-7C following the 2011 pump coupling failure. This review included the document review of post
-maintenance testing of the pump as well as documentation of pre-installation testing of pump and motor. Also reviewed was the completed work order for this repair and replacement
, and the material specifications (heat treat curves, hardness results) of couplings that were installed in this rebuilt pump P
-7C. Inspection Scope b. No finding s were identified Findings and Observations The inspectors did not identify any issues relating to the 2011 pump P-7C repair.
.4 Review information and processes relied upon by Palisades to determine whether or not critical attributes of service water pump line
shaft couplings, such as hardness, are acceptable prior to coupling installation a. . The inspectors reviewed the information provided by the licensee regarding pump shaft couplings that included hardness measurements at time of procurement, independent lab results for coupling hardness measurements prior to coupling installation in the pump s, and the associated heat treatments for the couplings.
Also reviewed were Inspection Scope industry reports and operating experience regarding use of 416 Martensitic SS for these couplings and the 2009 SW pump P-7C coupling failure root cause evaluation.
b. No finding s were identified
. Findings and Observations The inspectors identified a concern with the adequacy of specifying coupling hardness as the only critical material parameter. This wa s not a conservative approach given the collection of scientific literature and industry operating experience describing the vulnerability of 416/410 Martensitic SS to stress corrosion cracking
- and suggest ed use of toughness measurements in addition to hardness values to determine acceptability of 416/410 Martensitic SS as coupling material. However, ensuring hardness that values are below a certain allowable maximum , reduces the vulnerability of the couplings to I GSCC; but ha r dness itself may not be sufficient to ensure critical parameters are met.
This concern is captured as part of the URI included in Section
.07 of this report.
In late 2007 , an engineering change was initiated to replace the carbon steel components in the SW pumps with stainless steel components resistant to the erosion and corrosion issues the plant had experienced throughout its life. I n 2008 , couplings for the SW pumps were procured and fabricated from 416SS with specified criteria for material chemistry and a Rockwell C (Rc) hardness range of 28
-32 Rc. Information available from industry operating experience reference d that material, specifically water pump couplings , made from 410/416 SS were susceptible to IGSCC due to temper embrittlement and improper heat treatment.
The 2009 Palisades failure of SW pump P-7 C coupling was attributed to IGSCC due to significantly high hardness, ranging from 37
-41 Rc; and all couplings were replaced with the same material and design specification for hardness.
No additional criteria were specified for tempering or heat treatment.
Results from a similar coupling failure at Prairie Island in 2010
, showed that their coupling, supplied by same vendor as the Palisades pump couplings, failed due to IGSCC even though the hardness was near the specification criteria.
Absent any design criteria from the licensee, the heat treatment performed on the couplings was focused on the final product having a hardness value in the specified range of 28
-32 Rc. There was no consideration of the effect of heat treatment o n other material properties, such as toughness, that may affect susceptibility to IGSCC. The inspectors noted the heat treatments were different for couplings for each of the three pump s. Couplings for pumps P-7B and P-7C were double
-tempered. Also, the procedure used by the heat treatment vendor allowed multiple heat treatments (tempering) to achieve the desired hardness , and did not consider the affect of this process on IGSCC resistance.
Because of the literature and industry operating experience of the vulnerability of 416/410 Martensitic SS to IGSCC, the plant requested Structural Integrity to evaluate the ir 416SS couplings. The report was received in March 2011
, and suggested that the couplings were susceptible to temper embrittlement
, but did not conclude that there was an immediate operability concern. The plant was evaluating this information when the coupling failed on August 9.
.5 Evaluate the licensee's procedures and processes for evaluating/assessing the performance of vendors.
Emphasis should be placed upon determining why couplings that were believed to be of an appropriate hardness were later found to be of an inappropriate hardness. Review any evaluations/assessments of HydroAire that were completed by the licensee following the September 2009 service water pump P-7C coupling failure. Also, review any actions taken or direction provided by the licensee to HydroAire in response to the recent hardness test results
a. Inspection Scope
. The inspectors reviewed procurement procedures for the licensee and vendor, the 2009 root cause evaluation, source surveillance s completed since 2009, the industry audit of HydroAire, condition reports, corrective actions taken by the licensee and vendor after the 2009 coupling failure, purchase documents, and interviewed Quality Assurance personnel.
b. Findings and Observations
No finding s were identified
. The inspectors identified a concern that the licensee may not have provide d adequate vendor procurement control after the 2009 coupling failure
, which may have contributed to the 2011 coupling failure. The inspectors found that adequate procurement procedures and processes existed , but were not fully utilized after the 2009 coupling failure. This concern is included in the URI discussion in Section
.07 of this report
. The inspectors reviewed a vendor surveillance performed in March 2010 on parts for a spare SW pump. The surveillance noted that one pump part was heat
-treated , and the hardness reading s taken by the pump vendor and the heat treatment vendor were both out of the specified range. Therefore, the part was again heat
-treated, resulting in acceptable hardness values obtained by both vendors. The part was then identified as acceptable. This demonstrate d that as late as 2010, the re were still issues with the controls on heat treatment for SW pump parts.
Implementation of the corrective actions from the 2009 coupling failure resulted in some improvements to the vendor procurement processes and additional oversight.
This was based on: frequent vendor surveillance activities were conducted on new parts that found vendor performance was satisfactory
- procedure EN
-MP-100, "Critical Procurements
," was implemented for procurements after 2009; and a NUPIC [Nuclear Procurement Issues Committee] audit conducted in April 2011 found that HydroAire was implementing an effective quality assurance (QA) program.
This is not concluding the design criteria supplied to the vendor was correct
, as discussed earlier, only that the parts supplied by the vendor appeared to meet licensee criteria. No additional actions were taken by or required of the vendor after the 2011 coupling failure , since the licensee considered th is failure the result of activities that occurred in 2009 , and that corrective actions implemented by the vendor then were effective
.
.6 Evaluate the licensee's operating experience program with an emphasis on operating experience related to pump components manufactured by HydroAire.
Specific attention should be given to the licensee's evaluation of a 2010 service water pump coupling failure at Prairie Island and the evaluation of a March 2011 report from Structural Integrity regarding the potential for coupling failure due to temper embrittlement
.
a. Inspection Scope
Operating experience regarding failures of couplings using 41 0/41 6 Martensitic SS was reviewed along with generic technical reports and metallurgical reports. The report of most interest were the Prairie Island coupling failure in 2010, the Structural Integrity report which was issued to address the 2009 coupling failure at Palisades, and the 2009 Palisades coupling failure root cause evaluation
.
b. Findings and Observations
No finding s were identified
. The inspectors identified a concern that operating experience and industry information may not have been incorporated into the design of the pump nor addressed adequately in the 2009 coupling failure replacement and root cause evaluation. Further discussion of this concern is included in the URI discussion in section
.07. Operating experience that existed as early as 1991 discussed failures of pump couplings attributed to embrittlement of 410SS and 416SS due to improper tempering temperatures and heat treatment.
In addition, industry and NRC reports were available prior to 2009 and discussed the effect of temper embrittlement on 410/416SS material.
The SI report was issued in March 2011 , but the licensee did not accept the report until August. This report discussed temper embrittlement as an issue that could affect coupling reliability. The licensee had not yet evaluated nor initiated corrective actions base d on the report.
The inspectors found the licensee did identify pertinent operating experience in development of the 2011 coupling failure root cause evaluation, although the root cause report was not issued by the completion of th is SIT report.
.7 Review the licensee's root cause evaluation plan and schedule.
Include the schedule for performing testing of any components removed from pump P-7C. Evaluate whether the root cause evaluation plan is of sufficient depth and breadth. Confirm that the time allowed to perform the root cause evaluation is commensurate with the safety significance of this issue. Communicate to the licensee that the NRC will inspect the completed root cause evaluation and the associated corrective actions as part of our normal inspection activities
.
a. Inspection Scope
The inspectors reviewed the root cause charter, schedule, team make-up and action plan; and discussed actions with root cause team
. b. Observations The inspectors found the root cause team was comprised of individuals dedicated solely to the root caus e investigation
- they had no additional responsibilities. Most members had not been involved in the root cause for the 2009 failure. Team members included consultants
, including an independent pump manufacturer and the metallurgical lab contracted to perform the metallurgical analysis. The pump supplier, HydroAire , provided input to the root cause but was not a member. The root cause timeline started August 16
, and was scheduled to be completed within 30 days in accordance with procedures
. The root cause investigation was determined to be of adequate depth and breadth to be successful in determining the actual root cause. The action plan included the following aspects: improper hardness
- improper material
- over-torque from foreign material
- shaft m isalignment; Stress Corrosion Cracking
- incorrect clearances in coupling to shaft
- shaft faces not square
- pump alignment
- shaft wobble
- reverse rotation
- coupling defects
- operation at critical speed
- operation loads
- strainer blockage
- maintenance practices; and fatigue failure. The inspectors reviewed the draft metallurgical plan and considered the metallurgical analysis plan for selected coupling to be thorough, although the licensee had not yet finalized the plan or determined which couplings would be included in the plan.
The NRC will continue to inspect the metallurgical results and root cause report under the normal baseline procedures
.
Unresolved Item: Adequacy of SW Pump Couplings Introduction
- A URI was identified by the inspectors during review of the SW pump P
-7C coupling failure in 2011. Specifically, the inspectors were concerned with the adequacy of the procurement of the replacement couplings after the 2009 coupling failure on the same pump; whether operating experience was adequately incorporated into design specifications
- and whether the corrective actions taken after the 2009 failure were adequate to prevent recurrence.
Description
- Palisades has three safety
-related SW pumps that draw water from Lake Michigan to provide cooling to safety
-related and no n-safety-related components. Each pump has eight couplings to connect shaft sections. In 2009, the plant began a material change for the couplings and shafts from carbon steel to 416 Martensitic SS due to erosion issues of the carbon steel material. The material would be changed in series in of pumps P-7 A , P-7C, and P-7B respectively. The timeline (Attachment 3) includes specific dates
. In 2009 , SW pump P-7C failed due to cracked coupling #
7, resulting into entr y a TSAC , requiring the plant to shut down if the pump was not returned to service within 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br />. Metallurgical data on the failed coupling revealed the coupling hardness was significantly higher than the design specification. The specified hardness range was Rockwell C value of 28
-32 Rc. Hardness readings on the failed coupling ranged from 37
-41 Rc. The vendor, HydroAire, had supplied the couplings with certifications that the couplings were within the specified hardness
. This failure was entered into the licensee's corrective action program and identified as a significant condition adverse to quality (SCAQ).
At the time of the failure, no spare couplings were available. Immediate discussions with HydroAire ensued to obtain replacement couplings within the 72
-hour timeframe. Based on the hardness data received on the failed coupling, which conflicted with the certification received from the vendor, the licensee verbally imposed addition al requirements to obtain independent laboratory hardness checks on the replacement couplings.
The requirement for independent hardness checks on the replacement couplings was not incorporated into the procurement process. Procurement documents were not updated with this additional requirement , and procurement personnel, such as the licensee procurement manager at the vendor site or the plant receipt inspection personnel , were not made aware of the additional requirement. Procedure EN
-MP-100, "Critical Procurements," was not implemented even though criteria in the procedure, such as previous vendor issues, how critical the couplings were on plant operation, and the short procurement timeframe, appear to have been satisfied.
Eight replacement couplings were received and immediately installed in the pump
- the pump was returned to service within the 72
-hour requirement. Soon after the pump was returned to service, the licensee discovered that independent hardness checks were not performed. The vendor did provide certifications indicating that the couplings had hardness values in the specified range. An additional ten couplings were ordered and received soon after the pump was returned to service. Independent hardness checks completed on these spare coupling s agreed with vendor hardness results , thus providing some assurance to the licensee that the couplings currently installed in pump P-7C were of the correct hardness
. On August 9, 2011, SW pump P-7C was declared inoperable due to the failure of coupling #6. This failure was entered into the licensee corrective action program and identified as a SCAQ. The cause of the failure ha d not been determined at the time this SIT report was completed. However , hardness results obtained from an independent metallurgical lab from four of the in-service couplings, including the coupling that failed, were found to have at least one spot of higher hardness than specified, greater than Rockwell Hard ness value of 32 Rc. No hardness values approached the 37-41 Rc observed in the 2009 failure (the values were less than 34Rc). Therefore, the inspectors were concerned that the licensee did not ensure the vendor
-supplied coupling s with correct hardness values in 2009. Pending final results and conclusions from the metallurgical analysis and root cause analysis, the licensee may have failed to take measures in 2009 to assure that purchased material and equipment conform to the procurement documents, including provisions for, as appropriate, objective evidence of quality furnished by the contractor as required by Appendix B
. Operatin g experience available to the licensee from 1991 through 2009
, identified that Martensitic 416SS could be more susceptible to IGSCC
, dependant on the heat treating process. Some of the previous operating experience is listed below:
September 12, 1991
- Beaver Valley Unit 1 experience d a coupling failure of a Byron-Jackson centrifugal pump as a result of embrittlement of 410SS due to improper tempering temperatures and potential impurities.
The failure mechanism was IGSCC
- September 1, 1993
- NRC Information Notice 93
-68, "Failure of Pump Shaft Coupling Caused by Temper Embrittlement During Manufacture
," is issued informing licensees of problems stemming from temper embrittlement of 410SS supplied by Byron
-Jackson (referring to the 1991 Beaver Valley event)
- the document noted in the material analysis that the toughness of the failed component was extremely low
- September 22, 1993
- Indian Point Unit 2 experience d a pump failure due to a failed coupling attributed to a non-ductile fracture because of temper embrittlement of the 410SST used
- the failure mechanism was IGSCC
- September 1, 2003
- Perry Unit 1 experienced a coupling disassembly event on their emergency SW pump A. The failure mechanism was by IGSCC and no performance effects were noticed before the failure of the coupling
- May 21, 2004
- Perry Unit 1 experience d another emergency SW pump coupling failure; the failure mechanism was by IGSCC, similar to the 2003 event; 2006 - INPO Operating Experience Digest 2006 INPO release d a document that discusses SW pump (shaft, coupling and impeller) failures occurring in the industry. The report note d that 12 failures occurred between 1998 and 2006
, with the most frequent including corrosion causing coupling separation. One of the common causes identified was improper heat treatment of the material during manufacturing; and February 9, 2007
- NRC Information Notice 2007
-05, "Vertical Deep Draft Pump Shaft and Coupling Failures
," was issued and reference d the coupling failures from IGSCC that occurred at Columbia Generating Station. The couplings were 410 Martensitic SS and were susceptible to tempering embrittlement. The operating experience review identified at least 23 essential SW pump shaft and coupling failures since 1983 involving more than six different manufacturers.
The 2009 coupling failure root cause evaluation was focused on the material hardness. It did not fully evaluate the effect of other material properties, such as toughness which is discussed in the operatin g experience
, nor the change of material properties from heat treatment on the susceptibility of the couplings to IGSCC. Corrective actions after the 2009 failure did not address the heat treatment process. The inspectors were concerned that the licensee may not have adequately address ed operatin g experience in the design of the original 416SS couplings or the 2009 replacement couplings as required by Appendix B, Criteria II I. A nd the corrective actions taken after the 2009 failure may not have prevent ed recurrence of this SCAQ as required by Appendix B, Criteria XVI. These concerns will be further evaluated as part of the NRC baseline inspection program
, after the final metallurgical results are issued and the licensee root cause evaluation is completed.
(URI 05000255/2011012
-01; Adequacy of SW Pump Couplings).
4OA6 Meetings, Including Exit
On September 1, 2011, the special inspection team leader presented the preliminary inspection results to Mr. Anthony Vitale and members of his staff. No proprietary information is included in this inspection report.
ATTACHMENT:
SUPPLEMENTAL INFORMATION
KEY POINTS OF CONTACT
Licensee Personnel
- T. Vitale, Entergy/Site Vice President
- J. Haumersen, Entergy/System Engineering Manager
- B. Kemp, Entergy/Design Engineering Manager
- D. MacMaster, Entergy/Acting Design Engineering Manager
- D. Hamilton, Entergy/General Manager Plant Operations
- A. Blind, Entergy/Engineering Director
D.Malone , Entergy/Acting Nuclear Safety Assurance Dir.
- J. C. Plachta, Entergy/Quality Assurance Manager
- P. Deniston, Entergy/Sr. Engineer
- J. Forehand, Entergy/Engineering Supervisor
- B. Dotson, Entergy/Licensing
J.Pennington , Entergy/Corporate MP&C
NRC Personnel
J Ellegood , Senior Resident Inspector, Palisades
- J. Giessner, Branch Chief
- K. Stoedter, Acting Branch Chief
LIST OF ITEMS OPENED, CLOSED, AND DISCUSSED
Opened and Closed
None
Closed
None
Opened
05000 255/201 1 0 12-01 URI Adequacy of SW Pump Couplings
LIST OF DOCUMENTS REVIEWED