ML17250A891

LER 89-007-00:on 890619 & 21 Safety Injection Pumps B & C Inoperable Due to Assessed Design Flow Delivery Concerns. Caused by Recirculation Valves Being Full Open.Orifice Plates in Flow Loops Verified to Be correct.W/890719 Ltr

ML17250A891
Person / Time
Site:	Ginna
Issue date:	07/19/1989
From:	BACKUS W H, MECREDY R C ROCHESTER GAS & ELECTRIC CORP.
To:	NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
LER-89-007, LER-89-7, NUDOCS 8907280303
Download: ML17250A891 (12)

Text

A,CCELERATEDDlBUTIONDEMONSTIONSYSTEMREGULATORYINFORMATIONDISTRIBUTIONSYSTEM(RXDS)ACCESSIONNBR

8907280303DOC.DATE:89/07/19NOTARIZED:NOFACIL:50-244RobertEmmetGinnaNuclearPlant,Unit1,RochesterGAUTH.NAMEAUTHORAFFILIATIONMECREDY,R.C.RochesterGas&ElectricCorp.BACKUS,W.H.RochesterGas&ElectricCorp.RECIP.NAMERECIPIENTAFFILIATIONDOCKETg05000244

SUBJECT:

LER89-007-00:on890619,safetyinjectionpumpsinoperabilityconcernsduetoflowmetercalibrationerrors.W/8ltr.~DISTRIBUTIONCODE:IE22TCOPXESRECEIVED:LTRENCLSIZE:TITLE:50.73/50.9LicenseeEvent:Report(LER),IncidentRpt,etc.NOTES:LicenseExpdateinaccordancewith10CFR2,2.109(9/19/72).05000244RECIPIENTXDCODE/NAMEPD1-3LAJOHNSON,ACOPIESLTTRENCL1111RECIPXENTIDCODE/NAMEPD1-3PDCOPIESLTTRENCL11INTERNAL:ACRSMICHELSONACRSWYLIEAEOD/DSP/TPABDEDRONRR/DEST/ADE8HNRR/DEST/CEB8HNRR/DEST/ICSB7NRR/DEST/MTB9HNRR/DEST/RSB8ENRR/DLPQ/HFB10NRR/DOEA/EAB11NUDOCS-ABSTRACTRES/DSIR/EIBRGN1FILE01EXTERNAL:EG&GWILLIAMS,SLSTLOBBYWARDNRCPDRNSXCMURPHY,G.A111111111111111111111111111144111111ACRSMOELLERAEOD/DOAAEOD/ROAB/DSPIRM/DCTS/DABNRR/DEST/ADS7ENRR/DEST/ESB8DNRR/DEST/MEB9HNRR/DEST/PSB8DNRR/DEST/SGB8DNRR/DLPQ/PEB10NRRDREP/RPB10egREC02RES/DSR/PRABFORDBLDGHOY,A.LPDRNSICMAYS,G22112211101111111111221111111l.11NOTE'IOALLRIC6"R1KIPZEÃIS'IZASEHELPUS'IORXXQCBHASTE!CGMI'ACT'IHEDOCGMERI'ONGEALDESK,RXHPl-37(EXT.20079)K)XXi062QTBRX3RMMEPBCHDIPZBIBUTXCNLISTSFORDOCUMENTSKQDOHiTNEED)RIDSADDSFULLTEXTCONVERSIONREQUIREDTOTALNUMBEROFCOPIESREQUIRED:LTTR43ENCL42

$TCRGASA>VD.I'-CITRICCORPORATIONo89;=A~;,i,",,:NJ;.,">O',I<;.",',"July19,1989U.S.NuclearRegulatoryCommissionDocumentControlDeskWashington,DC20555

Subject:

LER89-007,SafetyIn)ectionPumpsInoperabilityConcernsDueToFlowMeterCalibrationErrorsCouldBeOfGenericConcernToNuclearIndustryR.E.GinnaNuclearPowerPlantDocketNo.50-244Inaccordancewith10CFR50.73,LicenseeEventReportSystem,whichpermitsandencouragesLicenseestoreportsigni-ficant,eventsthatmaybeofgenericinterestorconcerneventhoughtheymaynotmeetthecriteriacontainedin10CFR50.73,theattachedLicenseeeventreportLER89-007isherebysubmitted.Thiseventhasinnowayaffectedthepublic'shealthandsafety.Verytrulyyours,RobertC.MeGeneralManagerNuclearProductionxcoU.S.NuclearRegulatoryCommissionRegionI475AllendaleRoadKingofPrussia,PA19406GinnaUSNRCSeniorResidentInspector3907280303890719rDFlODOCK0~000244SPDC NACt>>e200IS021LICENSEEEVENTREPORTILERIUX.NVCLCA11lOULATOAYCOMMISSIONAttAOVlDOMSNO.2100OIOVCXtllll~0/SI/05tACILITYNAMCIllR.E.GinnaNuclearPowerPlantDOCSlTNVMStA(2)*06oo0244IOF10SafetyinjectionPumpsinoperabilityConcernsDueToFlowMeterCalibrationErrorsCouldBeOfGenericConcernToNuclea-IndusttVCNTOATlISILtANUMSCAIll1ttOATOATCIllOTHtAI'ACILITICSINVOLVCOISIIeONTHOAYYCAAYCAA~COUINTIALI)",AlVNIQNNUMetllcttNUMeellMON'THOAYYCAAtACIUTVHAULSOOCXCTNVMSCAISI06000061989890070007198906000OttAATINCMOOCIll~OrrlALCVSL099(10120.402(ol2ILe00(e)Ill(020.e004)IllIll20.e004)ll)IXII20.e004lll)(III20.e004)(1I(el20.400(el~0DS(el(I)SOW(el(21~0.224)(2)10~0.2541(2)I~I$0024I12IIXOI,ICCNSllCONTACTtOATHISLCA112150.22(el(2l(lrl00.254H2)(rll0.224)(2)lrel00.2241(2)I>>X)(Al~0.224)(2)(rNIISI50.224)(2)(el0THCAtOVIAtMCNTSOt10451)IICo>>eer>>er>>ereelMelerrerrert)ill)THIS1ttOATISSUSMITYCDtVASUANTT222(IS)12.1141DTHtAIte>>IIVMAereocte>>e>>errtleTecLHACt>>INHAMCWesleyH.BacksTechnicalAssistanttotheOperationsManagerTCLttHONlNUMSCAAAtACOOl315524-4446COMtLCTCONCLINCtOAtACHCOMtONCNTtAILUAtOCSCAI~CDINTHISAltOAT(12)CAV52tYSTCMCOMtONCNTMANVtACTVACAFek&v~k4kWCAUSCSYSTCMCOMtONCNTMANUSAC,TUACACtOATASLTONtAOSSUttLCMCNTALAltOATCXtCCTCOlie)YCS(Htre,CerVNr>>CXttCTCDSVSMISSIOHDATCIXNDAACTAAOTILervcIole00ieec>>,le,.ettroeerN>>ltIHIuovetreetuectteorlr>>exe>>IllsltXtCCTCDSVSMI$$IONOATSIll)MONTHCAYYCAAOnJune19,1989at1440EDSTwiththereactoratapproximately994fullpower-the<<B"and<<C<<SafetyIn)ection(SI)pumpsweredeclaredinoperableduetoassesseddesignflowdeliveryconcerns.Declaringtwo(2)SIpumpsinoperableplacedtheplantoutsidetheTechnicalSpecificationsrequiringaplantshutdown.WhileintheprocessofplantshutdowntheSIpumpflowswerereturnedtotherequiredflowratesbypumpminimumflowrecirculationlinevalvethrottling.OnJune21,1989at1401asimilarproblemoccurredwiththe<<B<<and<<C<<SIpumpsandplantmanagementdecidedtoshuttheplantdownuntiltheSIpumpflowconcernswereresolved.Theplantwasshutdownandsubsequentlycooleddowntolessthan350F.Originalcalibrationdataprovidedbytheplantdesignwasincorrectfortheinstalledapplication.Theunderlyingcauseoftheeventresultedfromincorrectoriginalcalibrationdata,providedbytheplantdesignerfortheinstalledsystem.N1Clore200(242)

IIACtea000AIM0ILICENSEEEVENTREPORTILER)TEXTCONTINUATIONU.LNUCLCAA004ULAfOAYCCXXXUWISI4tt+OVlOOQCIIO.4100&I/8axxtACSanIICSSACILlfYHAXICIllL0%IIIAX001ICIXXCUXttTIkL~tvtxtottItlt8~A40I3IR.E.GinnaNuclearPowerPlantTACTIllawe~4I+tvlwL~~IICICAxtx~'lll17l0500024489-007-0002of07PRE-EVENTPLANTCONDITIONSTheunitwasatapproximately994steadystatefullpowerwithnomajoractivitiesinprogress.ResultsandTest(R&T)personnelwereintheControlRoomdiscussingchangestoperiodictestprocedurePT-2.1(SafetyInjectionSystemPumps)withtheControlRoomoperators.ThesechangestoPT-2.1werenecessarytoreflectmodificationsmadetotheSafetyInjection(SI)pumpsminimumflowrecirculationlinesduringtherecentannualrefuelingandmaintenanceoutage.ThismodificationinpartincreasedthesizeoftheSIpumpsrecirculationlinestoincreasetherecirculationflowforbetterpumpreliability.DuringthepostmodificationtestingoftheSZpumps,the"B"and."C"SIpumpsexhibitedproblemsmeetingthedesignflowratestothereactorcoolantsystemasindicatedonSIflowindicatorFZ-925.Becauseoftheaboveindicateddesignflowratedeliveryproblems,the"B"and"C"SZpumpminimumflowrecirculationvalveswerethrottledto50gpmtoachievetherequireddesignflowratestothereactorcoolantsystem.Asthe"A"SXpumpdidnotexhibitproblemsachievingdesignflowratesto'heReactorCoolantSystem(RCS),itsrecirculationvalvewaslockedfullopen.II~DESCRIPTIONOP.ER"NTA.DATESANDAPPROXIMATETIMESFORMAJOROCCUEKENCESoJune19,1989,1440EDST:Eventdateandtime.oJune19,1989,1440EDST:Discoverydateyndtime.oJune19,1989,1440EDST:Startedunitloadreduction.oJune19,1989,1515EDST:UnusualEventdeclared.vttCxCAv0XAA000I IUICtone~IMMIHUCENSEEEVENTREPORTHLER)TEXTCONTINUAT!ONUSNUCLCArAIOULATCNY~ISI~rovaoOUCro.OIsoaICAcxiIrclc131esJACILIZYNAAICIIICOCKETIIUUCCWQlvtAALI1rlrICIOIQ$44UIIITIALMrvavIrUr~AOCISR.E.GinnaNuclearPowerPlantteer(A'~r1vrvrrL~~WC'IrrI~'11Imosooo2440070003OF10June19,1989,1615EDST:"B"and"C"SIpumpsdeclaredoperable.June19,1989,reduction.1615EDST:Stoppedunitload0June19,1989,1626EDST:minated.UnusualEventter-000June21,1989,1401EDST:StartedPT-2.1ontheSIpumps.June21,1989,1728EDST:Declaredthe"C"SIpumpinoperable.June21,1989,1915EDST:Startedunitloadreduction.0B.EVENT:June22,1989,0707EDST:ReactorCoolantSystem(RCS)coldlegtemperatureslessthan350FandRCSpressurelessthan1600psig.OnJune19,1989at1440EDSTthereactorwasatapproximately994fullpower.DuringdiscussionsintheControlRoombetweenR&TpersonnelandControlRoomoperatorsconcerningproposedchangestoprocedurePT-2.1,itbecameapparentthatthe"Band"C"SIpumpminimumflowrecirculationlinevalveswerelockedfullopenratherthantherecpxiredthrottledposition.TheOperationsShiftSupervisordeterminedatthistimethatifthe"B"and"CSIpumpswerenotalignedasperdesign,thenthepumpswereinoperableandthisplacedtheplantoperationsoutsideofTechnicalSpecification3.3.1.1.Cand3.3.1.4whichstatethefollowing:o3.3.1.1.C:Atoraboveareactorcoolantsystempressureandtemperatureof1600psigand350oFgexceptduringperformanceofRCSHydroTest,threesafetyinjectionpumpsareoperable.

NACFetes~I$4llUCENSEEEVENTREPORTILER}TEXTCONTINUATIONII.LNUCllAAAIOVLATOAYCAN%IONAtfAOVlOOUONO.)I94&I04CXAIACSenII99AACII.ITYNAMtIllOOCAITNUMlNQlL41NUU4l1I9I19OMAHfIAlUveaocHU~AOlIelR.E.GinnaNuclearPowerPlantTTSTIdaaae~NNWWC~~A9K'IAAA~'AlIITlo5ooo24489007-00040'3.3.1.4:Therequirementsof3.3.1.1.Cmaybemodifiedtoallowone.safetyinjectionpumptobeinoperableforupto72hours.BecausemorethanoneSIpumpwasdeclaredinoperable,thisplacedtheplant-inaconditioncoveredbyTechnicalSpecification3.0.1whichstatesthefollowing:oIntheeventaLimitingConditionforoperationand/orassociatedactionrequirementscannotbesatisfiedbecauseofcircumstancesinexcessofthoseaddressedinthespecification,within1houractionshallbeinitiatedtoplacetheunitinatleasthotshutdownwithinthenext6hours(i;e.,atotalofsevenhours),andinatleastcoldshutdownwithinthefollowing30hours(i.e.,atotalof37hours)unlesscorrectivemeasuresarecompletedthatpermitoperationunderthepermissibleactionstatementsforthe*specifiedtimeintervalasmeasuredfrominitialdiscoveryoruntilthereactorisplacedinamodeinwhichthespecificationisnotapplicable.BecauseoftheabovespecificationaunitloadreductiontohotshutdownwasstartedJune19,1989at1440EDST.Atapproximately1515EDST,June19,1989,theOperationsShiftSupervisordeclaredanUnusualEventinaccordancewithSC-100,"GinnaStationEventEvaluationandClassification"EAL:LossofEngineeredSafetyFeatures:exceedingaLimitingConditionforoperationonasafetysystemrequiringaplantshutdown;TechSpecsection3.3EmergencyCoreCoolingSystem.AlloffsitenotificationsweremadeperSC-601,"UnusualEventNotifications".NICIOlU)99A9QADI LICENSEEEVENTREPORT(LEA)TEXTCONTINUATION11.4.NUCI,CAN1!OQLAYOLYCOMMI&lOWAttLOVtOOM4NO.JlÃ&104CLiiLeealiieSLAClllYYNAMEillOOCLLYNVIMILQIL44NUMClL(411%4MLHTIAINVeaNNMN~A441$R.E.GinnaNuclearPowerPlantTKCfIII'MWL~NIOOeeC~~NICIINLI~'ll117)osooo24489-0070005OF10Atapproximately1615EDST,June19,1989subsequenttothesatisfactorytestingandthrottlingofthe"B"and"C"safetyinjectionpumpsminimumflowrecircula-tionvalvesto50gpm,the"B"and"C"safetyin)ectionpumpsweredeclaredoperableandtheloadreductionstopped.Withthe"B"and"C"safetyin)ectionpumpsdeclaredoperableandtheloadreductionstopped,theOperationsShiftSupervisor,"withapprovalandconcurrencefromthePlantManagerGinnaStation,andPORCdeclaredtheUnusualEventterminatedat1626EDST,June19,1989inaccordancewithSC-110,"GinnaStationEventEvaluationForReducingtheClassification".AlloffsitenotificationsweremadeoftheUnusualEventterminationandtheplantwassubsequentlyreturnedtoapproximatelyfullpower.OnJune21,1989at1401EDSTwiththereactoratapproximatelyfullpower,periodictestprocedurePT-2.1(SafetyInjectionPumps)wasstartedforthemonthlytestofthesafetyinjectionpumps.Thefollowingisasequenceofimportanteventsthathappened:The"A"SIpumpwastestedfirstandtestedsatisfactorily.Atapproximately1544EDST,uponstartingthe"B"SIpumpforthetest,thepumpminimumflowrecirculationflowratewasfoundtobe70gpm.Thiswascontrarytothe'required50gpmmaximumflowrate.Therecirculationflowratewasresetto45gpmperPT-2.1.0Atapproximately1637EDST,uponstartingthe"C"SIpumpforthetest,thepumpminimumflowrecirculationflowratewasfoundtobe56gpm.Thiswascontrarytotherequired50gpmmaximumflowrate.Therecirculationflowratewasresetto45gpmperPT-2.1.%1CiOAMWAY4II INCPensAIA1044ILICENSEEEVENTREPORTILER)TEXTCONTINUATIONU,l.ISUCLlAACl4ULATOIYC5++%$4SSAppsoYlooU4no.$190&I4slX~I'llSITIITSPACILITYNASSCIllOOCIIlTIIU~CWQlvSAALlkIIUSSOC1INSSOUSNSIALQsvissInvMs~j4lISIR.E.QianaNuc:learPowe-PlantneerIS'~~enWeeC~~P494Pens~'sIIITIosooo24489-007-0006ov10oAtapproximately1726EDST,the99B"andI9C99SZpumpswerestartedandstoppedtoverifyrecircflovwaslessthanor.equaltotherequired50gpm.Foundthe>>B"Slpumprecircflowat50gpmandthe"C"SZpumprecircflovat55gpm.oAtapproximately1728EDSTthe"C"SZpumpwasdeclaredinoperable.oAtapproximately1900EDSTameetingbetweenshiftoperationsandplantstaffwasconductedandthefollowingcourseofactionwasdecidedupon:1)Shutdowntheplanttolessthan350Fandlessthan1600psig,untiltheproblemwiththe"C"SIpumpminimumflovrecirculationlineflovrepeatabilityisfoundandcorrected.2)Resetthe"C"SIpumpminimumflowxecircu-lationflov.3)Testrepeatabilityofthe"C"SZpumpminimumflowrecirculationflov.4)Correctthecauseofpumpminimumflowrecirculationflowproblem.OnJune22,1989atapproximately0707EDSTthereactorcoolantsystemcoldlegtemperatureswerelessthan350FandRCSpressurewaslessthan1600pSigeC.D.INOPERABLESTRUCTURESPCOMPONENTSPORSYSTEMSTHATCONTRIBUTEDTOTHEEVENT:None.OTHERSYSTEMSORSECONDARYFUNCTIONSAFFECTED:None.vscpolUsess94SI Qecpena000AI%4SIUCENSEEEVENTREPORTILER)TEXTCONTINUATIONII~NLCLlANXlOOLATONTCaaaaWONAPPNOVlO440NO.)ISOMIOSlXtiAISSnIISSPACILITYNA4l111OOCXXTNV40SNISIvlAALlNNINS0l1IllSSOIISNTIALUVISIONNUa~AOlISIR.E.GinnaNUclearPowerPlantTENETINrane~0rsSUSSX~~ASICIreaa~'llIITI0500024489-0070007OF10E.METHODOFDISCOVERY'hefirsteventwasdiscoveredduringdiscussionsbetweenRETpersonnelandtheControlRoomoperators,concerningproposedchangestoPT-2.1.Thesecondeventwasdiscoveredduringthemonthlytestofthesafetyin)ectionpumps.F.OPERATORACTION:Thema)oroperatoractionduringtheeventswastoreduceplantloadandsubsequentlytaketheunitofflineandcooldowntolessthan350F.G.SAFETYSYSTEMRESPONSES:None.IIICAUSOPA.IMMEDIATECAUSE:The<<B<<and<<C<<SIpumpswerethoughttobeinoperablebecausetheycouldnotmeettheirdesignflowratestotheRCSduetotheirrecircvalvesbeingfullopenratherthanthrottledasrequired.B.INTERMEDIATECAUSE:00The<<B<<and<<C<<SIpumpminimumflowrecirculationvalveswerepositionedfullopenratherthanthrottledasrequired.Withthepumpminimumflowrecirculationvalvesrestoredtothethrottledposition,subsequent.pumptestingfailedtoachieverepeatablepumprecirculationflowresults.vaCPOAUSSSA9431~~V IICGYM500ALICENSEEEVENTREPORT(LER)TEXTCONTINUATIONIIA.NJCLCASI054UWTO4TCOINNKIOISktf0OVlOOM0IIO.5150%10455NA55lltt4$SACII.ITVHMI5IllOOCÃ5TIIU1%50IllYTAAI.I0IIIAN54IIISSOVSNYIAlMAV%IONM~A45I5IR.E.GinnaNuclearPowerPlantmCrIS~~e~~~ASSOIISMImauIITIosooo~4489007008oiC.ROOTCAUSE:Theunderlyingcauseoftheeventresultedfromincorrectcalibrationdata,providedbytheplantdesignerfortheinstalledsystem.ThecalibrationdataprovidedforflowtransmittersFT-924andFT-925didnotcorrelateaccuratelywiththeinstalledfloworificeplates,.FE-924andFE-925.ALYSIS0Theeventisbeingreportedinaccordancewith10CFR50.73LicenseeEventReportSystem,whichpermitsandencouragesLicenseestoreportsignificanteventsthatmaybeofgenericinterestorconcerneventhoughtheymaynotmeetthecriteriacontainedin10CFR50.73.Anassessmentwasperformedconsideringboththesafetyconsequencesand.implicationsofthiseventwiththefollowingresultsandconclusions:Therewerenooperationalorsafetyconsequencesorimplicationsattributedtothedeemedtobeinoperable"B"and"C"SIpumpsbecause:oAnanalysiswasperformedusingcurrentcalibrationdata,anditwasdeterminedthatevenwiththe"B"and"CllSIpumpsminimumflowrecirculationvalvesfullopen,theSIdesignflowratestotheRCSwerestillachieved.Thusthe'TBTTand"C"SIpumpswerenevertrulyinoperable.Basedontheabove,itcanbeconcludedthatthepublic'shealthandsafetywasassuredatalltimes.VAC+0AM)SSAtttl LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONV.E.NVCLEAAEE4VLAEO4YOSWE~ONAtMOYEOOMENO.$1%0MIOE~XWAESEnIIEEEACILITYNAMElllOOCEEYNV~EEIEIvEAALEiNVMEE1INEEOVENYIALHMNVoeNM~A4E101R.E.GinnaNuclemPowerPlantTEXrIIY~~4NeeeC~~AEECasa~'uImosooo2448900700090'0V.COCTIVEACTIONA.ACTIONTAKENORPLANNEDTOPREVENTRECURRENCE:0TheorificeplatesinstalledinSIflowloopsF-924andF-925wereverifiedtobecorrect.00oFlowtransmittersFT-'924andFT-925werecorrectlycalibratedtotheinstalledorificeplates.Thethreesafetyin)ectionpumpsweretestedwiththepumpminimumflowrecirculationlinethrottlingvalvesfullopen,andtherequiredSIdesignflowtotheRCSwasachieved.Allinstalledsafety-relatedfloworificeplateswereassessedforcorrectinstallationandcalibration.Correct,calibrationdatawasconfirmedforeachorifice/flowtransmittercombination.0Affectedcalibrationprocedureswerechangedtoreflectcorrectcalibrationdata.0ThenuclearindustrywillbenotifiedviaNUCLEARNETWORKofthegenericconcernsofcorrectcalibrationdataforfloworifice/flowtransmittercombinations.VACYOAMEEEA~E401 ACSana500A10451LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU~lg&l5AAA54UMYOAYCCWWNICSSASSAOVCOOU0HO.5150MIOS~5~IA555151I55SACICIYYIIAAI5lllOOCKSYAU~CAISISSAALCAAUSS051ISISSOUSASIAI,QVAIOA~tUA~AoaIaR.E.GinnaNuclearPowerPlantosooo244890070010OF10ADDITIONALINFORMATION:A.B.FAILEDCOMPONENTS:None.PREVIOUSLERsONSIMILAREVENTS:AsimilarLEReventhistoricalsearchwasconductedwiththefollowingresults:NodocumentationofsimilarLEReventswiththesamerootcauseatGinnaStationcouldbeidentified.C.SPECIALCOMMENTS:'one.wACsOlQSSSA0SSI