ML20058N716
| ML20058N716 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 09/21/1993 |
| From: | Date J, Rath C, Scow S ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR |
| To: | |
| Shared Package | |
| ML17310A702 | List: |
| References | |
| 93-02, 93-2, GL-89-01, GL-89-1, NUDOCS 9310200244 | |
| Download: ML20058N716 (150) | |
Text
{{#Wiki_filter:__ __ _ - - I k APS L Arizona Public Service Company l l INDEPENDENT SAFETY AhT QUALITY ENGINEERING DEPARTMENT GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAMMATIC ASSESSMENT TQE ASSESSMENT NO. 93-02
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GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAMMATIC ASSESSMENT TQE ASSESSMENT NO. 93-02 y MEMBERS. '
,'! '& 9l/7lf3 S. A. SMLead / Date Technical Quality Engineering h8$' 9//7/ff R. A. Whiting / Date / ' /
Ib 's ChubE'Rath /Wate Nuclear Engineering Valve Services Engineering ! k kh 9$h V J. L YoungfDate V Wm R. L Spencet / Date 9-/7-93 Technical Quality Engineering Quality Control i
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S. A. Bauer Nuclear Regulatory Affairs
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@EV!EWED BYj w.LJ C . L 9tnfg3 Michael E. Radoccia TECHNICAL QUAUTY ENGINEERING -
Supervisor
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l gPROVED BYj I\ r'} i >d n qjp',jg3 Ram N. Prabhakar INDEPENDENT SAFETY & QUAUTY ENGINEERING MANAGER i
c, TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT TABLE OF CONTENTS [ EXECUTIVE SUSIMARY ..................................ii I. PURPOSE ....................................... 1 II. ACTIVITIES / DOCUMENTS REVIEWED .................. 1 III. CONCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 IV. DEFICIENCIES ..................................33 V. RECOABIENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 VI. ATTACIIMENTS .................................35 Attachment A - Assessment Plan Attachment B - Cross-Utility Review of GL 89-10 Inspection Reports Attachment C - Assessment Database ; Attachment D - Assessment Sample MOV Spreadsheet Attachment E- Assessment Sample MOV Test Evaluation Status Attachment F - PVNGS GL 89-10 MOV Test, Evaluation, and Rework
- Process Attachment G - PVNGS GL 89-10 Implementation Schedule Attachment II- MOV Dynamic Testing Completion Status 9e
TQE ASSESShfENT NO. 93-02 GENERIC LETTER 89-10 Af0 TOR OPERATED VALVE PROGRAh! ASSESSAIENT EXECUITVE
SUMMARY
The objective of this assessment was to evaluate the implementation and overall effectiveness of the PVNGS Motor Operated Valve (MOV) program in accordance with the requimments and guidelines of NRC Generic letter (GL) 89-10, Safety-RelatedMotor Operated Valve Testing and Surveillance. A multi-discipline team comprised of engineers fmm Nuclear Engineering Department (NED), Valve Seivices Engineering (VSE), Technical Quality Engineering .(TQE), Nuclear Regulatory Affairs (NRA), and an inspector from Quality Control (QC) was assembled to perform this assessment. A MOV System Engineer from Washington Public Power Supply System (WPPSS) and two outside engineering consultants (Sargent
& Lundy and OGDEN) joined the team on a limited basis to provide an independent perspective.
The assessment included a review of program adequacy and implementation. The MOV program was evaluated against the program elements delineated in Generic Letter 89-10 as clarified in industry and NRC correspondence. A sample of 11 MOVs was selected to evaluate GL 89-10 program implementation. Selected design basis calculations, motor operator sizing and switch setting calculations, diagnostic test traces, and dynamic test data evaluations were reviewed for this sample of MOVs.
Conclusions:
The MOV Program has significantly improved since the first NRC inspection in 1991. ! Most of the programmatic issues identified during that inspection have been msolved, ! resulting in a much stronger program. MOV personnel have been reorganized to l improve coordination and effectiveness by combining maintenance and engineering 'i resources under a single manager. Continued strong involvement by program personnel in industry groups and with program vendors has resulted in keeping the program current with day-to-day changes and advancements in technology. Improvements have reduced Palo Verde's reliance on contract personnel. ii
TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT Performance of actuator refurbishment prior to static baseline and dynamic testing is a strength in the testing program. The program includes diverse measurements of critical parameters including stem torque. Procedures have been created to control evaluation of dynamic test data and to formalize MOV retest requirements. The initial static testing of MOVs is nearly complete, and approximately 60 percent of the valves have been dynamically tested, as a result of an aggressive test program being established and followed. Despite the anticipated conclusion of dynamic testing in accordance with the existing schedule, the scope of the GL 89-10 program needed to achieve completion of the progam is not clearly defined. Substantial additional work in the form of calculation revisions, valve modifications, and additional testing or a combination of these, remains to be completed. The pmgram does not delineate which of these activities needs to be completed in order to determine pmgram completion. In addition, the completion of the 1 design bases reviews and the resolution of a number of technical issues (e.g., degraded voltage, thermal binding and pressure locking, ambient temperafure effects, diagnostic uncenainties, etc.) also need to be considered in the definition of program scope. Regulatory documents defining the MOV Program requirements do not contain clear guidance as to what is required to consider the program complete. The development of a detailed pmgram scope document and schedule are necessary for determining if the committed schedule can be met. ; Based on the scope of activities reviewed during this assessment, it is concluded that the technical elements and programmatic controls of the MOV Program are adequate to I satisfy the requirements of GL 89-10. The deficiencies identified need to be corrected and, to further strengthen the pmgram, the recommendations and suggestions should be addressed and implemented, as appropriate. I E t i f k kki
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1 TQE ASSESSMENT NO.193-02 I GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT ! i 1 I.- PURPOSE i The objective of this assessment was to evaluate the implementation and' overall effectiveness of the PVNGS Motor Operated Valve (hf0V) program in accordance with , the requirements and guidelines of NRC Generic letter 89-10, Safety-Related Motor.- : Operated Valve Testing and Surveillance. II. ACTIVITIES / DOCUMENTS REVIEWED ! A. Assessment Scope k' An assessment plan was developed to determine the scope and completion schedule for this assessment. A copy of the plan is contained in ,; Attachment A.
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Due to the timing of this assessment, field observations of dynamic testing was , not practicable since these tests are typically performed during. scheduled j refueling outages. TQE will perform an independent follow-up observation of ! dynamic testing methodology during the Unit 1 (R4) outage. j The assessment was modeled after NRC Temporary Instruction 2515/109, l Inspection Requirementsfor Generic Letter 89-10, Safety-RelatedMotor-Operated , Valve Testing and Surveillance, Revision 1, and NRC Inspection Module 92701. -l Reviews were conducted in each of the following areas: ! I) Design Basis Review . . . . . . . . . . . . . . . . . . . . . '
- 04. 05 !
- 2) MOV Sizing and Switch Setting . . . . . . . . . . . . . . . 04.06
- 3) Design Basis Capability . . . . . . . . . . . . . . . . . . . -l 4) 04.07 ._j Periodic Verification . . . . . . . . . . . . . . . . . . . . . 04. 08 i
- 5) MOV Failure Trending 04. 09
- 6) GL 89-10 Program Schedule . . . . . . . . . . .. . . . . . . 04.10 i
- 7) MOV Design Control and Testing . . . . . . . . . . . . . .
04.1I i The assessment included an evaluation of program adequacy against the program :i elements delineated in Generic letter 89-10, as clarified in industry and NRC ~ l correspondence. The assessment also was used.to assist the. Valve Service j Department (VSD) in preparing for the upcoming Part 2 NRC Inspection. LThe 'I i i 1 H 9 -. ,m
TQE ASSESSMENT NO. 93-02 GENERIC LE' ITER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT programmatic issues identified in NRC Inspection Repon 91-25 were also evaluated, and inspection reports from other licensees were factored into the assessment. Attachment B contains a summary of issues identified from the review of other licensees inspection reports and includes an assessment of PVNGS's MOV program with respect to these issues. A sample of 11 MOVs (a vertical slice representation of approximately 10%) was selected, to evaluate program implementation. Selected design buis calculations, motor operator sizing and switch setting calculations, diagnostic test traces and dynamic test data evaluations were reviewed for the selected MOVs. Issues identified during the assessment were captured and categorized in a database to ensure each issue was adequately evaluated. The database is provided as Attachment C. Three levels of issues were identified in the database as follows:
+ Category I- Deficiency (requires corrective action)
+ Category II - Recommendations and Issues for Additional Review (require a response)
+ Category III - Suggestions for Improvement NQ_T_E:
i Category II items include programmatic issues of interest identified by the Assessment Team, the NRC Pan 2 Inspection Guidelines, NRC inspection reports of other utilities, and NUMARC. Because of time and resource constraints, all of these issues could not be reviewed during this assessment. These issues are included to assist VSE in preparation for the Pan 2 inspection. l 2 l
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TQE ASSESSMENT NO. 93-02 , GENERIC LETTER 89-10 : MOTOR OPERATED VALVE PROGRAM ASSESSMENT l i
-i B. Assessment Team :
1 l A multi-discipline team, comprised of engineers from Nuclear Engineering, Valve .; Services Engineering, Technical Quality Engineering, Nuclear Regulatory Affairs, and an inspector from Quality Control, was assembled to perform this assessment. t A MOV System Engineer from Washington Public Power Supply System , (WPPSS) and two outside engineering consultants (Sargent & Lundy and OGDEN) joined the team on a limited basis to provide an independent -! perspective.
-l C. MOV Sample Selection !
The following valves were selected for the assessment: [iQLY! FUNCTION ACIUATOR Cl/EURE E f CONTRf1 TYPE 6IZE !
!!AFBUV0034 AFW ISOLATION SMB-1
- TORQUE GATE / 6* 4 3JAFAUV0037 AFW ISOLATION SMB-1
- TORQUE GATE / 6" i
.i 3JNCNUV0099 NCWS ISOLATION MG00X ** LIMIT BUTITRIT.Y /14' !
2JSGNHVII44 AFW ISOLATION 16A
- TORQUE GATE / 6*
3JSGAUV0134 STM TO AFW TURB SB-0
- TORQUE GATTi / 6" '
IJSIBUV0626 HPSI FLOW CONT SMC.04
- TORQUE GIDBE / 2" IJSIDHV0331 HPSI IJT COO 11NG SMB-00
- TORQUE GIDBE / 3*
11SIAHV0657 S/D TEMP CONTROL SMB-00
- LIMIT BUTTERFLY /16* i 2JS!AUV0666 HPSI TO RWT ISOL SMC-04
- TORQUE GLOBE / 2*
2JSIAHV0672 COffT CS ISOL SB-0
- TORQUE GATE /t' '{
3JSIAHV0604 HPSI L/T COOLING SMB-00
- TORQUE GATE / 3" 'f NOTE: * - umiionia,** - ErM. a ~ - Roiort .cio.io,.
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Selection of the above valves was based primarily on marginal actuator capability. '{ Other criteria used for the selection included valve type / size, safety significance, ! Probabilistic Risk Assessment (PRA) evaluation, failure repons, and test results. d
' A spreadsheet containing data for the selected valves is provided in Attachment i D. '
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.i TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 :)
MOTOR OPERATED VALVE PROGRAM ASSESSMENT i D. Evaluation ! i 1.0 Design Basis Review (04.05) . 1.1 Summary l The design basis calculations originally provided by Combustion Engineering or generated by APS are currently being used in the ! GL 89-10 program. These calculations will be su'perseded by a revised analysis now under review by the Nuclear Engineering l Department to validate the analyses, incorporate the changes from , the recently revised emergency operating procedures, and remove : the excessive conservatism. Procedure 81DP-4DC10, Rev. 04, Motor Operated Valve Design Basis Review and Thrust / Torque Calculation, documents the methods to be used during ' design basis review and calculation of: minimum and maximum allowable thrust / torque values for pmgram MOVs. This procedure does not provide specific controls 3 to ensure that emergent, potential operability impacts are identified j and resolved in a timely manner. Additional procedural controls l are recommended to ensure that revisions to design basis and thrust / torque calculations are reviewed for impacts on completed' , dynamic test evaluations. 1 Calculation 13-MC-AF-401, Rev. 01 design basis calculation for i 13JAFBUV0034 and 13JAFBUV0035 was randomly. selected for ; detailed review, which confirmed that assumed variables are . conservative and that justification is docursented for Jeach ; assumption. The design basis calculation was varified to comply i with the requirements of 81DP-4DC10. j The program was reviewed .to l determine if the' potential for ' ! pressure locking and thermal binding of gate valves was be_ing .; considered, and it was found that the existing design basis 1 -i calculations do not address these effects. . Although an initial . - evaluation of the thermal / pressure locking effect was performed j i
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TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 ; MOTOR OPERATED VALVE PROGRAM ASSESSMENT for all program MOVs on EER 90-XM-024, NED considers ; additional evaluation warranted because of the continuing occurrences of gate valve locking recently documented by the NRC in Special Study - Pressure Locking and Thermal Binding of Gate Valves. Identification and evaluation of the flex-wedge gate valves most susceptible to thermal / pressure locking will be performed concurrently with the design basis review (CRDR 9 0561.01). 13-EC-MA-221, ACDistribution Calculation, issued on 07/30/93, was performed to replace out of date loading, voltage regulation, and short circuit calculations. This calculation has not yet been incorporated into 13-JC-ZZ-201. The results of this calculation - were compared with 13-JC-ZZ-201 for six of the valves in the assessment sample. The degaded voltage assumptions of the thrust / torque calculation for three MOVs (lJSIBUV0626, s 2JSIAUV0672, 2JSIAUV0666) do not envelop the degraded i voltages predicted by 13-EC-MA-221, and may not be ' conservative. Action to incorporate the AC Distribution , Calculation into 13-JC-ZZ-201 is being tracked by CRDR 910070.03. The degraded voltage calculation for randomly selected DC MOV ; 3]AFAUV0037 was reviewed to identify the methodology used to 1 determine the worst case MCC voltage and motor terminal voltage. The assumed battery voltage was confinned to agree with the i minimum voltage at the last minute of Station Blackout, derated i for aging, as calculated in 13-EC-PK-161, Class 1E Battery .'~ Minimum Tenninal Voltage Calculation. The minimum MCC voltage was conservatively calculated on the basis of connecting cable resistance and the maximum load of the battery load profile. 1 The resistance for the connecting cable from the MCC to the motor terminal was confirmed to agree with that calculated in 13-EC-PK-A03, Class 1E DC Cable Sicing. This resistance was ! i calculated on the basis of characteristic resistance per foot of ! conductor plus two times the thermal overload resistance, I corrected to 90 C. The temperature correction applied to cable 5
O+ Y i TQE ASSESSMENT NO. 93-02 i GENERIC LETTER 89-10 1 MOTOR OPERATED VALVE PROGRAM ASSESSMENT , resistance based on 90*C was found to be conservative with [ respect to the design basis temperature of 120*F for the main.
. steam support structure below 100 ft elevation shown in UFSAR i
Table 3E-1, Environmental Qualfication Parameters. The i effective motor resistance was calculated on the basis of rated -! motor voltage and stall current obtained from motor performance curves. The minimum voltage was determined based on the - minimum MCC voltage, the loop msistance, and the effective : motor resistance. The methodology reviewed was considered to be conservative and acceptable. 1.2 Conclusions f The design basis calculations of record will be superseded by new i calculations which ensure GL 89-10 issues' are adequately .; addressed. Completion of the revised calculations in accordance. ; with the current program schedule will result in compliance with -! GL 89-10. l t The program does not yet address thennal binding and pmssure locking of gate valves. Identification and evaluation of the flex-wedge gate valves most susceptible to these phenomena will be d perfonned concurrently with_ the design basis review. , The degraded voltage assumptions of the thrust / torque calculation > do not envelop the degraded voltages predicted by 13-EC-MA-221, and may not be conservative. Action to incorporate the AC Distribution Calculation into 13-JC-ZZ-201 is being tracked by l CRDR 910070.03.
}i 1.3 Deficiencies None
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, -_ m_ _ __ - _______m._________._ _-.__-_._.____ _ _ _ _ _ . - _ _ _ _ . _ _ _ _ . _ _ _ _ _ _ _ _ _ _
D TQE ASSESSMENT NO. 93-02 > GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT 1.4 Recommendations f i Revise procedure 81DP-4DC10, Motor Operated Vah'e Design Basis Review and Thrust / Torque Calculation, to include specific controls to ensure that emergent operability impacts am identified and resolved in a timely manner. ; Revise 81DP-4DC10 to include specific controls to ensure that ' revisions to design basis calculations and thrust / torque calculations are reviewed for impact on completed dynamic test procedures and evaluations. Additional recommendations are included in Attachment C. , 2.0 MOV Sizing and Switch Setting Calculations (04.06) 2.1 Summary i Calculation 13-3C-22-201, MOV Thrust, Torque, and Actuator , Sizing Calculation, includes a computerized spreadsheet template { designed to perform actuator sizing and calculate stem l thrust / torque requirements on the basis of given process and configuration variables. The template is used to calculate the ' minimum required and maximum allowable stem thrust / torque for l program MOVs. This calculation was reviewed, and validations l of the algorithms used in the template were found documented in the form of hand calculations. For gate valves, the algorithms were confinned to relate packing friction load, piston effect, ,q differential pressure load and seating load to calculate a net required stem thrust. Differential pressure loads are determined using the assumed valve factor methodology. This methodology is common within the industry and similar to that published in the i EPRI Application Guide for Motor Operated Valves in Nuclear l Power Plants. Although the relationship used is not the same as that published by EPRI, it is considered to be conservative and acceptable. l 7 i
TQE ASSESSMENT NO. 93 ! GENERIC LETTER 89-10 '! MOTOR OPERATED VALVE PROGRAM . ASSESSMENT ; i i The algorithms used to model Limitorque actuator performance are ( in agreement with the standard vendor equations. Adjustments to '; the minimum and maximum design thrust / torque values 'to- ; compensate for running load, diagnostic equipment inaccuracy, and j torque switch repeatability are documented in Appendix K of the l calculation. 1 i Calculation 13-JC-ZZ-201 Appendix K adjustments for torque ! switch repeatability and diagnostic inaccuracy were reviewed in an ~ l attempt to confirm consistency with ER-5.0, ITI MOVATS Incorporated Equipment Accuracy Summary and Limitorque l Maintenance Update 92-2. However, the Instrument Inaccuracy i
& Torque Switch Repeatability Table shown in Calculation Change i Notice (CCN) 9 to 13-JC-ZZ-201, Revision 1, is not provided with - '
supporting calculations and assumptions. Therefore, the values in this - table were not verified. Appendix K includes ER-5.0, '
. Revision 4, which has been superseded by Revision-5 ~ issued ,
Febmary 5,1993. The inclusion of the superseded report has no ; impact on the calculation results, because the later revision made
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no changes to the individual component accuracy claims. Instructions have been added to the Unit 1 Interim Controlled Motor Operated Data Bases (ICMODBs) and are scheduled to be ,
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added to the Urdt 2 and Unit 3 ICMODBs (CRDR 9-2-0071.08 and .09) requiring the field personnel to inform Engineering of any [ MOV with an as-left torque switch setting of "1". These j instructions are provided so that setpoints can be recalculated using , the appropriate torque switch repeatability identified by Limitorque ! Maintenance Update 92-2. The methodology used to ensure that ! switch settings incorporate diagnostic inaccuracy and torque switch repeatability margin was considered adequate. t Appendix K of Calculation 13-JC-ZZ-201' does ' not address ' adjustment of thrust / torque setpoints to compensate for ambient-temperature effects on motor torque output, lubrication degradation effects, or simultaneous seismic effects. An action is assigned l under the MOV Program to account for ambient temperature- l effects on motor torque output (CRDR 930431.04). : Lubrication ' ! 8
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s ~ i TQE ASSESSMENT NO. 93-02 l GENERIC LETTER 89-10 : MOTOR OPERATED VALVE PROGRAM ASSESSMENT : degradation is addressed by an existing field instmetion which l requires the switch settings to be adjusted high in the acceptable range. The calculation includes an assumption that an adjustment
- to compensate for seismic loading simultaneous with hf0V .j actuation is not required. j The myiew of Calculation 13-JC-ZZ-201 identified the calculation -i of a "D/P Test Correction Factor" applied to some hiOVs to l compensate for additional thrust / torque loading and load sensitive .
behavior effects observed during dynamic testing. This factor ; includes an adjustment based on the diffemnce between maximum ! thrust / torque measured during dynamic testing extrapolated to the ! design basis condition, and the minimum calculated thmst/ torque. l This factor also includes an adjustment for load sensitive lehavior i based on dynamic test measurements. The load sensitive behavior ! adjustment is not extrapolated to design _ basis conditions. l Incorporation of the D/P Cormction Factor into'the calculated ' setpoint range is the chosen method to ensure that dynamic test-results are conservatively incorporated in the switch settings. This ] method is an interim measure until additional test data can le i accumulated to support evaluation and possible revision of l thmst/ torque calculation assumptions using " type" comparisons and 1 statistical techniques. This method is considered conservative: because it increases the minimum thrust / torque setpoints to equal ! the as-left setpoints of successfully tested Af0Vs. It is suggested that NED provide procedural guidance on the determination of D/P Test Correction Factors. l Thrust / torque calculations for the eleven hf0Vs in the. assessment j sample were reviewed for consistency, and were verified to the l requirements of ' 81DP-4DC10. Two of the calculations _ (13SIDHV0331, 3JSIAHV0604)' determine maximum allowable l thrust values on the basis of an assumed stem friction coefficient ! of 0.12. This value is slightly more conservative than the value of- l 0.1 typically assumed in the maximum thrust calculation. One :! calculation (2JSGAUV0134) determined a minimum close thrust ! on the basis of an assumed application factor of 0.92. This value f I 9 i I I t
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-TQE ASSESSMENT NO. 93-02 l GENERIC LETTER 89-10 j MOTOR OPERATED VALVE PROGRAM ASSESSMENT i i
is slightly less conservative than the value of 0.9 typically assumed ! in 13-JC-ZZ-201, but the difference is not' considered to be ! significant. The application factor of 0.9 assumed for the other l MOVs was confirmed to agree with Limitorque Technical Update ! 92-0? ! l The review of the thmst/ torque calculation for IJAFBUV0034 ; confinned that worst-case conditions from the design basis ! calculation are used as input and that ajustification is provided for j each assumed variable. The assumed value for pullout efficiency ! of 0.40 and application factor of 0.9 were confirmed to agree with j vendor information recently published in Limitorque Technical : Update 92-02. Reference 7.54 on input sheet GAAF-34 refers to a superseded revision of the design basis calculation - 13-MC-AF-401. This later revision does not impact the existing i calculation results. i l Appendix K, Note 9, of thrust / torque calculation for 2JSGNHV1144 indicates that the minimum required open/close [ setpoint cannot be achieved without exceeding : the actuator -
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published torque /thmst rating as well. as the motor torque requirements. The note states that the setpoints'cannot ensure full operability of the MOV under' design basis conditions, and adds i that although the MOV is not safety related, it is 'important to _ j safety" and may have to be operated ~in accordance with plant ( emergency operating procedures. CRDR 230551 was initiated to i evaluate the impact of Appendix K Note 9 on the Auxiliary I Feedwater operability requirements of Technical Specification j 3.7.1.'2. 7 i I During recent dynamic tesdng, the sister valve, 2JSGNHV1142 [ failed to fully close. The evaluation of the test failure (CRDR' ' 0230455) determined that the impact on system operation is. minimal and initiated actions to revise emergency and normal l operating procedures to reduce the worst : case . design basis { differential pressure conditions. Actions have been assigned * (CRDR 0230455.04 & .05) to revise the design basis calculation : r 10 -!
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l TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT and thmst/ torque calculation after the procedum revisions are completed. The Design Maximum Closing Thrust and the Adjusted Maximum r l_ Total Closing Thmst values specified by the ICMODBs (i.e., EERs 93-MO-017, 93-MO-005, 92-MO-175) for the five Limitorque gate MOVs in the selected sample were compared with published actuator thrust ratings. The comparison indicated that I the specified maximum closing thmsts am within published actuator thmst ratings. Increased thmst ratings based on Kalsi data were not used. In addition, the 13-JC-ZZ-201 gate valve template , l was reviewed to confirm that the stall torque equation published in l Limitorque Maintenance Update 92-1 is not used in the calculation l of maximum thrust / torque values. The review confinned that l motor torque limit determinations are properly based on a calculation involving motor starting torque, gear factor, overall l gear ratio, pullout efficiency, application factor, and minimum voltage. However, review of maximum open and close thmst ! calculations showed that detennination of the " motor torttue limited," " actuator torque limited," and " valve torque limited" conditions are based on an assumed stem friction coefficient of 0.1. This assumption is potentially nonconservative, and a technical justification for its use was not found. Review of assumptions contained in 13-EC-MA-221, AC Distribution Calculation, showed that the degmded voltage calculations properly consider effects of sequenced operations during both the Loss of Offsite Power / Forced Shutdown (LOP /FS) , and Iess of Offsite Power / Loss of Coolant Accident (LOP /LOCA). The insulated cable resistances used as input to
- Calculation 13-EC-MA-221 are based on 90 C rather than the l temperatures identified in UFSAR Table 3E-1, Environmental Qualifcation Parameters. Nojustification could be found for this engineering assumption (Per VSE the 90' C is an industry standard engineering assumption).
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TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT 2.2 Conclusions Ambient temperature effects on motor torque output must be ' incorporated into the calculations or otherwise resolved. The methodology used to ensure that switch settings incorporate diagnostic inaccuracy and torque switch repeatability margin was considered adequate. The algorithms used to model Limitorque actuator performance are in agreement with the standard vendor equations. Adjustments to the minimum and maximum design thmst/ torque values to compensate for mnning load, diagnostic equipment inaccuracy, and torque switch repeatability are documented. The calculation includes a "D/P Test Cormction Factor" that is applied to some MOVs to compensate for additional thrust / torque loading and load sensitive behavior effects observed during dynamic testing. The degraded voltage calculations properly consider effects of sequenced operations. 2.3 Deficiencies , The insulated cable resistances used as input to Calculation 13-EC-MA-221 are based on 90*C rather than the temperatures identified in UFSAR Table 3E-1, Environmental Guahfcation i Parameters. No justification could be found for this engineering i assumption. CRDR # 9-34)709 was initiated to evaluate the adequacy of the assumption. , CRDR # 2-3-0551 was initiated to evaluate the impact of Appendix
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K Note 9 on the Auxiliary Feedwater operability requirements of Technical Specification 3.7.1.2. 2.4 Recommendations Revise calculation 13-JC-ZZ-201, Appendix K, to delete reference to the mperseded ER-5.0, Revision 4, and to include supponing - . calculaticas and assumptions for the Instrument Inaccuracy & Torque Suitch Repeatability Table. 12
TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 i MOTOR OPERATED VALVE PROGRAM ASSESSMENT Determination of the "mo:or torque limited," " actuator torque limited," and " valve torque limited" conditions in the calculation [ of maximum thmst for rising stem valves is based on a potentially ; nonconservative stem friction coefGeient assumption of 0.1. A ; technical justincation for its use should be documented. The methodology used to calculate and apply the D/P Test + Correction Factor" should be explained in 13-JC-ZZ-201. t Additional recommendations are included in Attachment C. 3.0 Design Basis Capability (04.07) ' s 3.1 Summary i The review focused on the aspects of the MOV Program which , demonstrate the capability of MOVs to perform their intended functions at or near design basis conditions. The scope of the MOVs in the GL 89-10 pmgram is defimed and documented. The ; valves have been prioritized for testing according to their functional imponance. Documented explanation was not found for i those MOVs where testing at design basis diffemntial pressure or flow is not practicable.
- Out of the eleven (11) actuators selected for the assessment I sample, ten (10) had been tested. The results of these tests are !
described in Attachment E. VSE's review of the ten (10) test' I results packages determined eight (8) of the actuators either did not meet acceptance criteria, and/or wem disquali6ed due to test or [ equipment methods. In the cases where the MOV did not satisfy the preestablished acceptance criteria, further documentation (CRDR) had been initiated to evaluate operability. CRDR evaluations determined that cc:aponent operability was not impacted by the unacceptable /aisqualiGed test results. Refer to Attachment F for a flow chan repmsentation of the process. The j majority of the MOVs evaluated were not tested at design basis ! conditions. By procedure (39DP-9ZZ01), in situ testing will lx: [ i 13
TQE ASSESSMENT NO. 93-02 , GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT considered complete when a test is performed at or as close as practicable to design basis conditions, or by a Phase 1 evaluation and justification for not performing additional testing. CRDR actions evaluated the need to perform additional testing of 4 valves from the assessment teams list. This selection was based on valves in which Phase I testing had been performed. Altemate methodologies had been used where testing at design basis was not practicable. 39AC-92Z01, Section 2.3.7.1, states VSE is responsible for defining alternate evaluation methods where testing at design basis is not practicable. Three (3) MOVs were chosen for an in-depth myiew, including test results, Test Instructions, engineering data evaluations, and follow-up responses. These included 1JAFBUV0034 (tested 2/91), 3JAFAUV0037 (tested 5/91) and 2JSGNHV1144 (tested 6/93). In each case, the MOVs did not pass their acceptance criteria. MOVs IJAFBUV0034 and 3JAFAUV0037 wem disqualified as a result of the type of test equipment used. CRDRs # l-3-0220 and 3-3-0183 wem dispositioned for actuators lJAFBUV0034 and 3JAFAUV0037, respectively to suppon continued operability. ; t Test data reviewed for valve 2JSGNHV1144 showed this actuator ' had passed only pan of the required acceptance criteria. Research found an outstanding open EER # 91-SG-170 (dispositioned 11/91), stating that the actuator may not operate at design basis DP conditions. Sister actuator 2JSGNHV1142 failed to perform its intended function at design DP during testing, supporting the disposition of EER 91-SG-170. CRDR 2-3-0455 was initiated for the failure of 2JSGNHVll42 and was dispositioned (8/93) to '; revise the operating procedums to lower the design system differential pmssures. The EER and associated Plant Change Request were held open due to depanmental engineering differences which were settled with the disposition of CRDR 2 , 0455. Test Instructions did not pmvide sufficient guidance to the personnel performing the tests to ensure design DP and flow will j 14 s
t TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 t MOTOR OPERATED VALVE PROGRAM ASSESSMENT be met. The tests that were reviewed focused on the differential pressure obtainable, without consideration as to flow. Flow, where used, (e.g. not a concem during hydro testing) is a natural outcome of the differential pressure across the valve. . The process used to evaluate the test data consists of taking the , resulting variables obtained from diagnostic testing and performing , an evaluation (Evaluation Data Sheets) for each of the parameters that are imponant in meeting an established testing criteria (one Evaluation Data Sheet for each parameter). The sheets contain the formulas required to assess the parameter being evaluated and the result of this manipulation for comparison to the published design values. Those parameters that do not pass the test, are evaluated for operability impact using the CRDR process. Procedural controls have been established to ensure that dynamic . test data is evaluated in a timely fashion. Some of these t evaluations determined that the MOVs did not pass the acceptance criteria established in the data sheets on some of the parameters. : CRDRs were written to assess valve operability and have determined that funher evaluation would be required. i Dynamic tests performed at less than design basis differential I pressure require an engineering evaluation involving extrapolation to demonstrate design basis capability. These extrapolations i should be considered as the first stage of a two stage approach, ar.d technical justification for the method of extrapolation used should be considered as part of the second stage. 39DP-9ZZ01 1 does not require extrapolation adjustments for evaluation of . dynamic test data collected at less than design basis conditions. [ Operability evaluations of " Unacceptable" test results include extrapolation adjustments to design basis conditions. " Acceptable" ! test results collected at less than design basis conditions do not receive extrapolation adjustments. It is recommended that VSE review 39DP-9ZZ01 to determine if extrapolation adjustments are required during evaluation of test data collected at less than design ! differential pressure. r n 15 k i
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~ TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT - - 1 1 Procedure 39DP-9ZZ01 does not inchide an evaluation of thermal- a overload sizing based on test amperage data nor does it specify a - maximum allowable inaccuracy for the dynamic test evaluations. ! Some evaluations have been completed with. overall . system inaccuracies as high as 80 percent. The recorded uncenainties are ; the result of using the best available test methods at the time the test was performed. VSE has indicated that ' these high uncertainties are included in the evaluation process. It is recommended that VSE review the testing methodologies used to-reduce test result uncenainty. Pmcedum 39DP-9ZZ01 specifies that, for gate and globe valves, the evaluated open peak cracking stem torque not exceed the
" Required Stem Torque" value specified in 13-JC-ZZ-201.
The open peak cracking torque evaluation for 3JSIAHV0604 incorrectly compared the measured peak cracking torque of 27.4 ft-lbs against the " Unit Rated Torque" of 250 ft-Ibs. The Required Stem Torque as shown in 13-JC-ZZ-201 is 130 ft-lbs. The error may have been the result of table look-up crmr or a misinterpretation of the fonn's line item description. The numerical comparisons performed in the dynamic test evaluations are not currently required to be independently reviewed. For a limited number of gate and globe MOVs, the calculated " Required Stem Torque" exceeds the valve open weak' link torque limit. Therefore, the existing evaluation methodology should be revised to include a comparison of measured peak cracking torque with the } lesser of valve " Weak Link Torque," " Valve Seismic Torque," and
" Unit Rated Torque."
Review of 3JSIAHV0604 dynamic test data evaluation, noted that the MOVATS NOR files had to be corrected to reflect proper pressure transducer span number input. The open and close thrust NOR files also required correction. 39DP-9ZZ01 includes a verification of correct transducer conversion factors. CRDR # 9 0691 was initiated to address the correction and administrative control of MOVATS diagnostic NOR files. 16 H
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TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT Lack of a document trail between WOs, VSE Data Evaluations, and the msuhant CRDRs, were identified as a program weakness. Procedure 39DP-92201, PVNGS Guidelines for Evaluation of Motor Operated Valve Dynamic Test Data, specifies that a CRDR be initiated when the acceptance criteria has not been met. However, when a MOV did not meet acceptance criteria, there was no provision for placing that actuator back into the Program Schedule. Presently the CATS action process tracks further actions for retest, but in the cases reviewed, the retests fall outside of the GL 89-10 response date (CRDR l-3-0216). Procedure 39DP-9ZZ01 Section 3.5.5 requims that the responsible engineer select the evaluation crieria and methods depending on design basis requirements, MOV configuration, and dynamic test methods used. Section 3.5.6.3 requires the evaluation criteria "Open Stem Factor" to be applicable to flow over-the-seat (OTS) globe valves. An evaluation was not performed for Opening Stem Factor for the OTS globe valve IJSIDHV0331. 3.2 Conclusions Even though there wem some minor weak areas identified, over all, the program as proceduralized adequately addresses the intent of GL 89-10. Test methods, equipment, and current technologies combined with the follow-up evaluations indicate the competency and dedication that PVNGS has to the MOV program. 3.3 Deficiencies
- CRDR # 9-3-0691 was initiated to address the correction and administrative control of MOVATS diagnostic NOR files.
Opening Stem Factor for the over the seat globe valve IJSIDHV0331 was not perfonned. CRDR l-3-0453 was initiated to perform the required evaluation. 17
- 3. ;
TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 [ MOTOR OPERATED VALVE PROGRAM ASSESSMENT ; 3.4 Recommendations
. f
.i Review 39DP-9ZZ01 methodology used to evaluate open peak I cracking torque for globe and gate MOVs. Consider the need for 1 an independent myiew of dynamic test evaluation numerical !
comparisons. t Review the testing methodologies used to reduce test result uncenainty. l s Review 39DP-92Z01 to determine if extrapolation adjustments are required during evaluation of test data collected at less than design , differential pressure. : i Provide documented explanation for those MOVs where testing at design basis differential pressure or flow is not practicable. + Develop a formal plan to ensure that Phase I MOVs are capable , of functioning at maximum design basis parameters. Revise 39DP-9ZZ01 to docurrent thermal overload sizing and test amperage (FLA & LRA) parameters.- Revise 39DP-9ZZ01 under static testing to include the requirement that dynamic test data evaluated as " acceptable" be forwarded to { i NED for thrust / torque calculation impact review. l Revise 32MT-9ZZ56 to include measurements of torque to evaluate performance with respect to motor, valve, and actuator l torque limits. Additional recommendations are included in Attachment C. ! 5 i i 18 ! i
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L - , , l TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT 4.0 Periodic Verification (04.08) 4.1 Summary The NRC has recommended that the surveillance interval be based 1 on the safety imponance of the MOV as well as its maintenance history, but that the interval should not exceed 5 years or 3 refueling outages. Computerized work order tasks are automatically generated on a refueling outage frequency. Computerized work order tasks from Model Work Orders are being developed to completely refurbish the GL 89-10 operators on a frequency of every founh refueling (CRDR 910064.05, 06 & 07). GL 89-10 MOVs are to be refurbished on an "as needed" basis prior to performance of a dynamic test. Procedures have been established which will identify grease degradation in MOVs. The inspection of the grease is thomugh in i that the internal cavity areas are viewed by removing the motor and the limit switch assembly. This inspection is performed by PM Tasks generated automatically on a refueling outage schedule. This is viewed as a' strength in the program. The Generic Letter requires licensees to ensure correct switch settings are maintained during the life of the plant. Statements - found in recent NRC Pan 2 Inspection Repons indicate that those licensees intending to satisfy this commitment on the basis of periodic static testing will be required to provide documented justification supponing a reliable correlation between MOV static and dynamic capability. This justification will be required within the schedule requirements of GL 89-10. Review of the existing implementation plan and program documents failed to identify the justified methods to be used to ensure that correct switch settings are maintained during the life of the plant. 39AC-9ZZ02, Valve Senices Maintenance, Appendix G, pmvides a matrix for 6termining the post maintenance testing required depending on the maintenance performed. The matrix funher establishes requirements for "as found" and "as left" testing. All I
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TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT MOV maintenance activities have been included within this matrix. The 39TI series procedures are used by VSE engineers to perform dynamic tests. The data is transferred from the 32MT-9ZZ56 procedure to the Test data evaluation forms controlled by the 39DP-9ZZ01 procedure. Engineering then perfonns a detailed analysis of the data to ascertain if the valve _ will function per design. The results of the engineering evaluation am not controlled and do not receive an independent review to ensure accuracy. However this data is govemed by the requirements of a quality assurance record and based on recent problems in the area of data evaluation control (CRDR l-3-0453) found during this assessmeat, the QA organization feels that this falls under Section 4.2.1.2 of the Operations QA Plan and the data should be controlled. 4.2 Conclusions Existing procedures and programs result in performance of preventive maintenance tasks on a regular frequency. Although the interval has not been adjusted to compensate for component
- safety significance or maintenance history, it does satisfy NRC requirements.
Existing procedures adequately identify retest requirements for specific corrective maintenance performed on MOVs. Existing implementation plan and program documents do not identify and/or justify methods to be used to ensure that the required dynamic capability of program MOVs is maintained during the life of the plant. 20
TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89 MOTOR OPERATED VALVE PROGRAM ASSESSMENT 3 4.3 Deficiencies Identified Dynamic test data is not being contmiled as a quality assurance record as required by the Operations QA Plan. CRDR l-3-0426 was initiated. 4.4 Recommendations Preventive Maintenance Equipment Qualification (PM EQ) Maintenance Work Tasks #047415 (Valve #037) and #048565 (Valve #0604) all reference Maintenance per 32MT-9ZZ48. This procedure has been cancelled according to DDC. The tasks referenced require updating to reflect the correct procedure. Investigate the possible correlation between static and dynamic capability tojustify the periodic verification of dynamic capability on the basis of static testing. Additional recommendations are included in Attachment C. 21
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TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT 5.0 A10V Failure Trending (04.09) 5.1 Summary A review of hiOV failure data for the 11 valves in the assessment - sample was conducted to determine the adequacy of the Failure Data Trending (FDT) program (NPRDS). The data was reviewed _ to determine if mot cause of failure was being evaluated when-appropriate, and to ensure these failures were being trended. Root cause of failure is being evaluated when appropriate and the valves are being properly trended by the FDT program. The review also determined that there was consistency between the NPRDS database and the SIhiS database. Procedures need to be established by VSD to programmatically. capture the GL 89-10 commitments to failure trending. The NRC recommends that procedures be established to analyze as-found deteriorated conditions, malfunctions, tests, inspecdons, and repairs or alterations on hiOVs. This data is required to'be periodically reviewed (every 2 years of after each refueling. ou* ge). Procedures need to define the necessary parameters to be et .ned from the FDT Coordinator. The procedures should also l specify the various departmental responsibilities. The FDT l program was queried using valve identification numbers to produce ' information on valve type and function of a specific valve using the valve identification number only. The information obtained indicated that the data could be retrieved in such a manner as to indicate function and type of valve, if so requested. Performance Engineering is responsible for hiOV performance trending as delineated in Section 3.5 of Procedure 39PR-9ZZ01. A database is currently being developed by Performance Engineering for trending historical data, and is scheduled to be on-line on or before the currently committed completion date for the GL 89-10 program. The database will trend limit switch settings, running / inrush current, stroke time, lubrication, spring pack displacement, and tortive/tluust values. The process of 22
TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT j 1 l l obtaining data for the performance monitoring database is not progmmmatically controlled and not all relevant data is being ) captured. The conclusions reached by the use of this data may not , be accurate. It is recommended that the accuracy of the t information be verified either before or after data is entered. , GL 89-10 indicates that "Each MOV failure and corrective action taken, including repair, alteration, analysis,' test, and surveillance, ! should be analyzed or justified and documented." Data from dynamic tests are evaluated and classified as " acceptable," ,
" unacceptable," or " disqualified;" however, " unacceptable" data .-
are not included in the performance trending program. ITI MOVATS ER 5.2, Limitorque Actuator Open vs. Close TMD Data Analysis Procedure has been used in various calculations (EER 92-MO-179) but is not controlled. This ER has not been -; incorporated into VTM M459-001. 5.2 Conclusions j Trending through NPRDS has resulted in significant improvements since 1991. The FDT data base can be queried to search for a variety of subjects. This program meets the requirements of GL ; 89-10. I Historical data trending is weak. The process of obtaining data for the performance monitoring database is not programmatically ' controlled and not all relevant data is being captured. The .i conclusions reached by the use of this data may not be accurate. It is recommended that the accuracy of the information be verified , either before or after data is entered. 23 i
TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT l l' 5.3 Deficiencies The process of data gathering for MOV performance shrul6 be ~ programmatically controlled to ensure all relevant data is captured '. in a complete and accurate database. CRDR 9-3-0689 was initiated. l - ITI MOVATS ER 5.2, Limitorque Actuator Open vs. Close TMD Data Analysis Procedure has been used in various calculations (EER 92-MO-179) but is not controlled. This ER has not been . incorporated into VTM M459-001. CRDR 9-3-0690 was initiated. 5.4 Recommendations Verify performance trending data before and/or after data entry. Consider " unacceptable" data from dynamic tests for inclusion in the performance trending program. Procedures need to be established by VSD to programmatical.ly capture GL 89-10 commitments to failure trending. Procedures need to define the necessary parameters to be obtained from the FDT Coordinator. The procedures should also specify the various departmental responsibilities. Additional recommendations are included in Attachment C. 6.0 GL 89-10 Program Schedule (04.10) 6.1 Summary APS committed to comply with the program schedule suggested in GL 89-10, Motor-Operated Valve Testing and Surveillance, with one exception. This commitment requires APS to complete the program for each unit within five years or three refueling outages of June 28,1989. The one exception was described in a January 24
m TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT 10,1992 letter to the NRC wherein APS informed the NRC that the schedule for Unit 2 would be extended through the 5th refueling outage or approximately 90 days beyond the five year time frame delineated in the generic letter. The APS MOV program schedule tracks the completion of motor operator rewiring and initial static and dynamic testing. The rewiring of MOV actuators is complete. Attachment G depicts the current schedule for completion of the mmaining initial static and dynamic tests and includes some valves designated for retesting. The schedule will result in the completion of the remaining initial static and dynamic tests by the committed end date of the program. Initial static tesdng is 99 percent complete in Units I and 2 and 96 percent complete in Unit 3. As shown in Attachment H, initial dynamic testing is currently 41 percent complete in Unit 1 (and is scheduled to be 73 percent complete following refueling outage IR4), 74 percent complete in Unit 2, and 53 percent complete in Unit 3. Extensive evaluation and corrective actions (i.e., revision of MOV i calculations, valve modifications, and/or valve retesting) may be required following dynamic testing as depicted in Attachment F. These activities are not included in the program schedule. From discussions with Valve Services Department personnel it has been concluded that the scope of the pmgmm required to be complete to satisfy GL 89-10 has not been clearly defined. The generic letter requires that the NRC be informed, if the pmgram schedule cannot be met.
^
g NUMARC and the NRC were contacted regarding the scope of activities required to be complete in order to consider the GL 89-10 program complete. Both organizations indicated this has not been clearly defined. The NRC indicated 'an internal workshop was going to be conducted to address this issue. In general, the ' representatives of these orgamzations indicated that to achieve f-closure, MOVs within the pmgram need to be set up based on 25
-l TQE ASSESSMENT NO. 93-02 -l GENERIC LETTER 89-10 -i MOTOR OPERATED VALVE PROGRAM ASSESSMENT. j i
dynamic test data and valve operability needs to be demonstrated. The NRC recommended the development of a detailed plan and -! corresponding schedule which describe the activities which APS- 1 intends to conduct by the completion date of the program. This ; schedule should be available on site for NRC review. If this - i schedule changes the current commitment to the NRC, then it ! should be submitted to the NRC in : accordance with the : ; requirements of GL 89-10. : The design basis review process represents a significant program .i activity with potential impact on thrust / torque calculations. -The { status of the design basis calculation review process. however, is ; not periodically updated. ; t 6.2 Conclusions ! The entim scope and schedule of the~ program to satisfy the f mquimments of GL 89-10 have not been clearly defmed.. 1 6.3 Deficiencies None . 6.4 Recommendations ! l The GL 89-10 Implementation Plan should be revised to more [ thoroughly define the scope of the program. A revised program i schedule should be developed and, if necessary to meet the I requimments of GL 89-10, submitted to the NRC prior to the upcoming MOV team inspection. i The design basis calculations status should be updated periodically, j 1 26 [ [
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TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 MOTOR OPERATED VALVE PROGRAM ASSESSMENT < 7.0 MOV Design Control & Testing (04.11) 7.1 Summary Design Control The Operations Quality Assurance Plan states that controls must be in place for the establishment of design changes. The QA Plan also states that the design bases, safety analysis, design criteria, codes and standards, and Plant Technical Specifications, including all amendments, shall be translated into design documents and reviewed during the design process. The following procedures ' were reviewed to ensure that they meet the requirements of the QA Plan:
+ 83PR-0CC01, Rev. 00.03, Configuration i Management Program
+ 81DP-0TR01, Rev. 1.05, Nuclear Engineering Division Qualification and Training i
+ 81PR-0DC02, Rev. 3, Plant Change Progmm j
+ 81 AC-0DC01, Rev. 4.03, Procedure for Design Change These procedures meet the requirements set fonh in Section 3.2,-
Design Control, of the Operations Quality Assurance Plan. The
)
procedures provide the programmatic requirements to ensure that design change documents are controlled and will include all the areas outlined in the QA plan. 81DP-0TR01 requires that only qualified individuals initiate design change documents and that l those individuals meet the requirements of Section 2.7 of the Operations Quality Assurance Plan. l l-h. i
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.g f 1 TQE ASSESSMENT NO. 93-02 4
. GENERIC LETTER 89-10 i 7
i MOTOR OPERATED VALVE PROGRAM ASSESSMENT l q t , i 1 Testing Procedure 39PR-9ZZ01 requires the valves in the MOV progmm to be dynamically tested prior to the closure date of the GL 89-10 .! commitment. Test failures are documented via the CRDR process j for dynamic tests and on EERs for static tests. The static and { dynamic test parameters are set per ICMODBs which have been i established for interim control of the torque and thrust settings. f Testing failures caused by hardware failures are captured under the NPRDS (FDT) for trending. 7 i The assessment team reviewed the procedures used for diagnostic i testing. Maintenance procedure 32MT-9ZZ56 has undergone- ! extensive review and modifications, and is now easier to read and ; more comprehensive. The 39TI series procedures are used by VSE engineers to perform dynamic tests. The data is transferred. ! from the 32MT-9ZZ56 procedure to the Test data evaluation fonns I controlled by the 39DP-9ZZ01' procedure. Engineering then-performs a detailed analysis of the data to ascertain if the valve : - will function per design. QA Involvement I t i To ensure compliance with applicable regulations and i requirements, PVNGS oversight groups conducted ' audits and assessments of the MOV Program in accordance with the PVNGS j1 Operations Quality Assurance Plan. I q i F F t 28 j
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h a l TQE ASSESSMENT NO. 93-02 i GENERIC LETTER 89-10 j
% FOR OPERATED VALVE PROGRAM ASSESSMENT ;
The following is a list of significant PVNGS oversight activities ; related to the MOV program-
+ 03/91 U-3 Outage Modification Emluation (TQE) i
+ 07/91 CAR 91-0021, EERs Improperly Used (TQE) :
+ 11/91 FE 91-34, Safety-Relared MOVSwitch Setting (ISE) !
+ 08/92 QDR 92-013? Control and Maintenance of ;
Computer Sof are (QA&M) I The NRC has noted a lav - ochnical monitoring to determine ! overall adequacy of the MOV activities. Subsequently, ' NRC . l Inspection Report 93-17 stated that QA involvement in the ; initiation and closure of CAR 91-0021 was strong. QA has r displayed an aggressive mle in bmadening the scope of concems j and elevating problems to appmpriate levels of management.
)
2 The assessment team also looked at Quality Contml activities i penaining to MOVs. QC has implemented a plan to cross-train j individuals in valve service maintenance, including diagnostic ' evolutions. Quality Contml has recently scheduled maintenanc_e j training on various MOVs (the same training technicians receive) ! and has assigned inspedors'to Valve Services Maintenance to obtain first-hand experience on the disassembly / reassembly of ; MOV actuators. Plans to include inspectors in the MOVATS -i diagnostic training in the future will add to the technical expertise H of QC inspectors. The involvement of Quality Assurance in the
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MOV Pmgram has been limited and needs to be strengthened. Training o Training and personnel qualifications of the Vaive Service
'l Department were reviewed. Two engineers in VSE were not current on their required training.
s 29
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TQE ASSESSMENT NO. 93-02: , GENERIC LETTER 89-10. l MOTOR OPERATED VALVE PROGRAM ASSESSMENT ! i Training Procedure 15DP-0TR66 was reviewed and it was noted - l that Sections 3.4.2 and 3.5.5 of the pmcedure reference appendices in procedure 15AC-0TR01 which do not exist. 15DP- 1 OTR66 needs to be revised to reference the correct procedum. , Appendix M, of 15DP-0TR66 applies only to the Valve Service i Maintenance Personnel. The training requirements for the MOVATS 3000/3386 series training is specified in Appendix M under course numbers NVM06, NVM07, 'and NVM10.' These numbers could not be cross-referenced to Section' 4 of the procedure which lists the prerequisites as well as the retraining ; intervals. 15DP-0TR66, Section 3.5.2, states that the Site ' Maintenance andModifcation Training Program is organized into courses and these courses are implemented in settings that may . consist of classroom, training laboratory, computer-based, self- .l study, on-the-job and vendor presented training. Section 3.5.3 j states that courses shall be successfully completed to establish and
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maintain qualifications, however, training necessary to obtain and ! continue to maintain qualifications for MOVATS is not def'med.- ! The initial selected training courses (Section 4.0) am mquired to -i have the retraining intervals . listed for. the Valve Service : Technicians who are qualified for MOVATS Tesdng. , PVNGS has committed to INPO to provide 16 hours 'of training in MOV Industry Events and 16 hours of position specific training. l A review of records indicate that members of VSE have received -i mom hours of training than was committed. In addition, several members of VSE are active members of the MOV Users Group , (hR/G). The knowledge level and experience of program personnel - is considered to be a program stmngth.
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i TQE ASSESSMENT NO. 93-02 i GENERIC LETTER 89-10 ! MOTOR OPERATED VALVE PROGRAM ASSESSMENT l 7.2 Conclusions , I i Programmatic controls have been established in the area of design control which meet the requirements of the Operation Quality ' Assurance Plan. j Quality Assurances involvement in the MOV Program is limited.
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Although QA has taken a strong position on cenain issues, QA's l overall involvement should be increased. l Appendix M and Section 4.0, of 15DP-9TI.66, need to mference ; the requirements for MOVATS qualification for initial and 't continuing training, with retraining intervals delineated. ! 7.3 Deficiencies i i None ! t 7.4 Recommendations ' Increase overall QA involvement in the MOV Program. . L Revise 15DP-0TR66 to reference the correct procedure. l 1 Additional recommendations are included in Attachment C. j u i i i 31 I i _ _ _ _ _ _ _ _. I
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i TQE ASSESSMENT NO. 93-02 GENERIC LETTER 89-10 ; MOTOR OPERATED VALVE PROGRAM ASSESSMENT i i III. CONCLUSION i The MOV Program has significantly improved since the first NRC inspection in 1991. l Most of the programmatic issues identified during that inspection have been resolved, I resulting in a- much stronger program. MOV personnel have been reorganized to improve coordination and effectiveness by combining maintenance and engineering resources under a single manager. Continued strong involvement by program personnel j in industry groups and with program vendors has resulted in keeping the program current ) with day-to-day changes and advancements in technology. Improvements have reduced l Palo Verde's reliance on contract personnel. Performance of actuator refurbishment < prior to static baseline and dynamic testing is a strength in the testing program. The i program includes diverse measurements of critical pammeters including stem torque. ! Procedures have been created to control evaluation of dynamic test data and to formalize MOV retest requirements. The initial static testing of MOVs is nearly complete, and ! approximately 60 percent of the valves have been dynamically tested, as a result of an f aggressive test program being established and followed. Despite the anticipated conclusion of dynamic testing in accordance with the existing . , schedule, the scope of the GL 89-10 progmm.needed to achieve completion of the - ! program is not clearly defined. Substantial additional work in the form of calculation revisions, valve modifications, and additional testing or a combination of these, remains i to be completed. The program does not delineate which of these activities needs to be ; completed in order to determine progam completion. In addition, the completion of the design bases reviews and the resolution'of a number of technical issues (e.g., degraded voltage, thermal binding and pressure locking, ambient temperature effects, diagnostic j uncertainties, etc.) also need to be considered in the definition of program scope. ; Regulatory documents defining the MOV Program requirements do not contain clear 1 guidance as to what is required to consider the program complete. The development of a detailed program scope document and schedule are necessary for determining if the , committed schedule can be met. { Based on the scope of activities reviwd during this assessment, it is concluded that the l technical elements and progmmrratic controls of the MOV Program are adequate to I satisfy the requirements of GL 89-10. The deficiencies identified need to be corrected .I and, to further strengthen the program, the recommendations and suggestions should be ! addressed and implemented, as appropriate. t i 1 32 4
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-l TQE ASSESSMENT NO. 93-02 l GENERIC LETTER 89-10 !
MOTOR OPERATED VALVE PROGRAM ASSESSMENT ~ i
.i IV. DEFICIENCIES i During the assessment several deficiencies were identined and CRDRs were written. [
These deficiencies are categorized by assessment topic and presented below: j LQ5 Desien Basis Review I None identified. ; LQ6 MOV Sizine and Switch Settine Calculations i The insulated cable resistances used as input to Calculation 13-EC-MA-221 am based on ! 90*C rather than the UFSAR design basis accident temperatures No justification could 'i be found for this engineering assumption (Per VSE, the 90* C is an industry standard i engineering assumption). (CRDR # 9-3-0709) l The impact of Appendix K, Note 9 needs to be evaluated with mspect to the Auxiliary' Feedwater operability requirements of Technical Specification 3.7.1.2. (CRDR # 2 -l 00551). { 1 92 Desien Basis Capability ; i MOVATS diagnostic NOR files have a potential to be incorrect and are not properly ' controlled. (CRDR # 9-3-0691) l An evaluation was not performed for Opening Stem Factor for the over the seat glote i valve IJSIDHV0331. (CRDR # l-3-0453) !
-i 10.8 ' Periodic Verification "l Dynamic test data is not being controlled as a quality assurance record as required by the l Opemtions QA Program. (CRDR #9-3-0710) j l
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i i TQE ASSESSMENT NO. 93-02 l GENERIC LETTER 89-10 - MOTOR OPERATED VALVE PROGRAM ASSESSMENT l I 4.09 MOV Failure Trending The pmcess of capturing data for the MOV performance ' database needs to be ; programmatically controlled to ensure all relevant data is captured. (CRDR # 9-3-0689) ! A vendor document has been used to perform engineering evaluations though it is not ! controlled. (CRDR # 9-3-0690) 't 4.10 GL 89-10 Program Schedule None identified. 4.11 MOV Design Control & Testing None identified. V. RECOMMENDATIONS In the course of the assessment a number of issues were identified which the assessment team determined required a response from the responsible organization but which did not constitute a deficiency. Some of the more significant recommendations are delineated in the body of this report. An entire list of the recommendations is contained in Attachment C and can be identified in the database by their Category II designation, a 5 34 l w -
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TQE ASSESSMENT NO. 93-02 ! GENERIC LETTER 89-10 i MOTOR OPERATED VALVE PROGRAM ASSESSMENT l VI ATTACIBfENTS : Attachment A - Assessment Plan Attachment B - Cross-Utility Review of GL 89-10 Inspection Reports 1 Attachment C - Assessment Database j i t Attachment D - Assessment Sample MOV Spreadsheet !
'I Attachment E - Assessment Sample MOV Test Evaluation Status !
i Attachment F - PVNGS GL 89-10 MOV Test, Evaluation, and Rework Process i Attachment G - PVNGS GL 89-10 Implementation Schedule . l Attachment II- MOV Dynamic Testing Completion Status : i f I
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i i TQE ASSESSMENT NO 93-02 l E GENERIC LETTER 89-10 l MOTOR OPERATED VALVE PROGRAM ASSESSMENT l J c i ATTACHMENT A ; i ASSESSMENT PLAN !.
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r PVNGS MOTOR OPERATED VALVE PROGRAMMATIC ASSESSMENT Independent Safety & Quality Engineering , Assessment Plan July 1993 I
- 1. OBJECTIVE The objective of this assessment is to evaluate the impiementation and determine the effectiveness of the ,
PVNGS Motor Operated Valve (MOV) program with respect to Generie letter 89-10,
- Safety-Related i Motor Operated Valve Testing and Surveillance," to ensure that MOVs are capable of performing their intended safety functions.
II. SCOPE This assessment will include a review of the MOV program for safety-related systems in accordance with Generic Letter 89-10 and evaluate the implementation of the generic letter by sampling MOVs for a detailed review. Ill. ASSESSMENT TEAM r
'The assessment team will be comprised of individuals from the following organizations:
Orcanization Proieeted Sunnort ISQE 2 Engineers (including the Team 1. cad),1 Specialist Engineenng (MOV Group) 1 Engineer Engineering (Design) 1 Engineer NRA 1 Consultant QC 1 Inspector ! Other Utilities (SONGS, Diablo Canyon) I to 2 EnF ineers / Consultants IV. SCHEDULE r Assessment Milestones Est Duration Forecast , Draft Assessment Plan 7/7/93 Identify Assessment Team Assessment Team Kick-off Meeting Finalize Assessment Plan Management Notification Perform Assessment 4 Weeks Evaluate Results / Develop Conclusions 4 Days Draft Final Report 1 Week Review issues with Impacted Organizations Incorporate Comments / Suggestions Approve and issue Final Report Exit Meeting 9/1/93 Assessment Lead: Stuart Scow Ib - Date Y8N3 i Assessment Approval: Ram Prabh / / Date 7 7 b 3
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TQE ASSESSMENT NO 93-02 -) GENERIC LETTER 89-10 ' MOTOR OPERATED VALVE PROGRAM ASSESSMENT ATTACIBfENT B ; CROSS UTILITY REVIEW OF GL 89-10 INSPECTION REPORTS i I i 1 l I i
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PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B" CROSS UTILITY REVIEW OF NRC GL 89-10 INSPECTION REPORTS NRC Inspection Report Comments Utility MOV MOV Assessment Remarks Assessment The inspectors noted that the methods used to evaluate 1,5,8,1I PVNGS 39DP-9ZZ01 does not extrapolate test results to RFI 04.07.01 data from design basis testing did not ensure that MOVs design basis conditions where applicable. VSE to review could perform their safety function under design basis the need to perform extrapolation adjustments during conditions. "The inspectors explained that since most of evaluation of dynamic test data obtained at less than the dp tests were performed at less than full dp, an engi- design basis conditions. neering evaluation of the test results was required in order to demonstrate design basis capability of each MOV." Inspectors considered these extrapolations to be the first stage of a two-stage approach, and stated the licensee is expected to justify the method of extrapolation by GL 89-10 schedule completion date. One licensee agreed to change procedures and program as required to provide a short term evaluation of dynamic test results prior to return of an MOV to service,includ-ing extrapolations to design basis conditions. Similar changes would be made for a long term evaluation of dynamic test results, including such considerations as valve factor, stem friction coefficient, and available mar-gin. The licensee indicated that static testing would be used 1, 2, 5 PVNGS has not established correlation between static Weakness for periodic verification to assure that proper switch set- and dynamic tests. RFI 04.08.04 tings are maintained during the life of the plant. However, the licensee had no objective evidence to establish a reli-able correlation between static and dynamic tests. The inspectors indicated the licensee must establish such a correlation before static tests can be used for this purpose. Licensee did not plan periodic refurbishment. 1 PVNGS program requires periodic refurbishment. Strength
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PVNGS GL 89-10 MOV ASSESSMENT ATTACHMENT "B" - " CROSS UTILITY REVIEW OF NRC GL 89-10 MSPECTION REPORTS h!OV NRC Inspection Report Comments Utuity MOV Assessment Remarks Licensee did not plan to dynamically test MOVs if at 1. 5 PVNGS intends to perform a dynamic test on all program RFI 04.07.10 least 80?c of design basis dp and flow could not be valves, as practicable. No minimum test conditions crite-achieved. NRR to review. ria has been established. Ilowever, PVNGS could save Inspectors were concemed that dynamic tests conducted resource by not dynamically testing MOVs if at least at d/p and flow significantly less than design basis indi- 807c of design basis dp and flow cannot not be obtained. cate characteristics of static tests and may be invalid. The licensee's MOV coordinator's close involvement in 1 PVNGS uses an MOV coordinator in support of outage Strength planned maintenance testing, static and dp testing was scheduling, refurbishment, rework, and retest activities. noted by the NRC as a program strength. The licensee's program for processing and control of 1, 4 Open item. RFI 04.03.09 operating experience and vendor notifications reviewed and found to be acceptable. The licensee's self assessment was performed with 1 PVNGS self assessment scope was opened to include all Strength appropriate depth and objectivity, but was limited in of the activities of GL 89-10. scope to just MOV setpoint control. The licensees use of PRA to prioritize MOV testing was 2 PVNGS uses PRA to prioritire MOV testing. Strength noted by the NRC as a program strength. The licensee could not produce a schedule outlining 2 PVNGS has a GL89-10 schedule summarir.ed in a memo- Weakness dynamic testing. This was noted by the NRC as a pro- randum from M.R.Ilooshmand to M.S.Coppock dated RFI 04.02.01 gram weakness. January 22,1993 (320-00236-MSC/MRil). The schedule should be revised to reflect present status, and also should be revised to address the additional retesting specified in the dynamic test CRDR evaluations. Licensee's increased management attention and staff 2,11 PVNGS has reorganized the Valve Services group to Strength coordination in the area of MOVs was noted by the NRC improve coordination and effectiveness. as a program strength. For a different utility, the inspector noted that the licensee had a designated group assigned to MOV maintenance. This was considered by the NRC as a program strength. _J - _ __ _ ___ _ _
PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B" CROSS UTILITY REVIEW OF NRC GL 89-10 INSPECTION REPORTS NRC Inspection Report Comments Utility blOV Assessment Remarks hlOV Licensee calculated that some of his blOVs have the 2 PVNGS has not tried to justify elimination of dp testing RFI 04.06.03 capability to support a valve factor of 0.5 and a stem fric- on the basis of actuator capability. Ilowever. PVNGS tion coefficient of 0.2. and licensee decided that because may potentially save resource by performing similar cal-of this substantial capability those hf0Vs would not be culations to identify those h10Vs with sufficient capabil-subjected to design basis testing. Inspectors were con- ity to justify deletion of design basis testing. cemed that this approach may not be bounding. Licensee agreed to refine the approach and include grouping to demonstrate that the methodology would be bounding for each group. The licensee's trending program covered an expansive 2 Open Item. RFI 04.02.17 range of data and appeared to trend all the known RFI 04.02.21 trendable parameters. This was noted by the NRC as a program strength. Licensee did not evaluate valve factors and motor capa- 2 PVNGS evaluates valve factor in both directions. Strength bility in the open direction. Licensee did not apply appropriate accuracy adjustments 2 PVNGS disqualifies test evaluations that involve test data Strength data outside the calibration range. recorded outside of correctable calibration limits. Licensee calculated valve factor based on thrust mea- 2. 5 PVNGS determines valve factor and stem factor based on Strength sured at seat contact. This point was not always the Idgh- tinust measured at point of maximum dynamic force. est thrust recorded in the stroke of the valve. Licensee calculated the stem factor based on CST instead of flow cutoff. Licensee uses a Potential Condition Adverse to Quality 3 PVNGS uses the CRDR program to ensure proper root Strength Report review process to ensure thorough root cause cause analysis and corrective actions. evaluations and conective actions. 'Ihis was noted by the NRC as a program strength.
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PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B"
- CROSS UTILITY REVIEW OF NRC GL 89-10 INSPECTION REPORTS NRC Inspection Report Comments Utility MOV Assessment Remarks MOV Assessment Licensee's design basis calculations of flowrate and dif- 3 PVNGS design basis calculations require review to Strength &
ferential pressure were not complete. This was noted by remove excessive conservatism, and compare calcula- Weakness the NRC as a program weakness. tions with the operating procedures to ensure that the RFI 04.06.09 worst case operating conditions are enveloped by the design basis flowrates and differential pressures. The review process id rigorous and detailed. Licensee's thmst calculations to support the program 3 PVNGS thmst and dp cales require incorporation of Weakness were not complete. This was noted by the NRC as a pro- revised degraded voltages and revised design basis flow RFI 04.06.24 gram weakness. and dp requirements. Licensee did not provide guidance for setting open torque 3 PVNGS does establish and provide guidance for the Strength switch settings.This was noted by the NRC as a program adjustment of open torque switch setpoints. weakness. Licensee had not completed significant number of dp 3 PVNGS has completed a significant number of dp tests. Strength tests. This was noted by the NRC as a program weakness. Licensee *s MOVs that were dynamically tested greater 3 PVNGS has not addressed the issue of periodic dp test- Weakness than five years ago had not been retested in accordance ing. RFI 04.08.04 with the recommendations for periodic verification con-tained in the GL. Inspectors considered the failure to complete the required periodic verification testing within a timeframe consistent with the GL to be a program weakness. Licensee did not formalize the post maintenance testing 3 PVNGS has formalized retest requirements into plant Strength requirements into procedure Tlis was noted by the procedures. NRC as a program weakness. ___..[ _ ___ - - - - -- - ---- - -- - - - - - - - - - - - - - - -
PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B"
- CROSS UTILITY REVIEW OF NRC GL 89-10 INSPECTION REPORTS NRC Inspection Report Comments Utility MOV MOV Assessment Remarks Assessment The licensee's degraded voltage cable resistances were 3 PVNGS degraded voltage calculation includes the RFI 04.06.10 based on 90 Celsius. Inspectors detennined that this assumption of 90 Celsius cable temperature.
assumption was non-conservative because cable tempera- Open item. tures inside containment may be as high as 128 Celsius during design basis event (LOCA). Cables in other parts - of the plant may be exposed to temperatures as high as 223 Celsius during some high energy line breaks. Inspectors noted the licensee's degraded voltage cales did 3 Open Item. RFI 04.06.12 not assume the worst case grid voltage as starting point RFI 04.06.13 per GL. Inspectors noted that margin to account for MOV degra- 3, 5 PVNGS thrust / torque calculations do not include a mar- RFI 04.02.05 dation was not included in the thrust calculations. gin factor to compensate for lubrication degradation over the maintenance interval. This issue is addressed by field instructions to adjust settings to the middle of the allow-able band. Inspectors noted that margin to account for rate-of-load- 3 PVNGS thrust / torque calculations include a d/p correc- RFI 04.06.06 ing effect was not included in the tinust calculations. tion factor to compensate for load sensitive behavior for some, but not all MOVs in the GL 89-10 program. The inspectors considered the licensee's lack of a fomial 3,4 PVNGS trending program not yet in place to record mea- Weakness trending program to be a program weakness. Trending sured valve factor, stem factor. RFI 04.09.03 parameters such as thrust, torque switch setting, valve factor, and stem factor were recommended. Licensee did not have a formal program in place to trend MOV degra-dation through use of as-found data. Inspectors noted that a program to specifically evaluate 3 PVNGS uses procedure 39DP-9ZZ01 to specifically Strength MOV test data was not in place at the time of the inspec- evaluate MOV dp test data. tion, and lack of an evaluation program was considered a program weakness. Acceptance Criteria needs to be clear, precise, concise and complete.
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PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B" CROSS UTILITY REVIEW OF NRC GL 89-10 INSPECTION REPORTS '. NRC Inspection Report Comments Utility MOV MOV Assessment Remarks Assessment Inspectors noted the program description was not current 4 PVNGS Implementation Plan is not current. Weakness and did not stand alone as documentation of GL 89-10 RFI 04.02.01 activities. Inspectors were concemed t!ut overly conservative val- 4,11 PVNGS is currently reviewing revised design basis cal- Weakness ues specified as design basis operating conditions did not culations to remove excessive conservatism, and identify RFI 04.06.09 clearly establish conditions for required MOV operabil- potential changes to operating procedures that would ity. Also, inspectors found that settings had been adjusted reduce the design basis requirements. He revised design based on unreviewed contractor design basis calculations. basis calculations have not been entered as input into the Inspectors concluded the licensee's program had not yet thrust calculations. adequately established the design basis for each MOV. During an inspection of a different utility, inspectors noted that all design basis reviews and initial calculations for valves considered necessary for Unit 1 operation had been completed. This was considered by the NRC as a program strength. Licensee imposed margins (0.5 valve factor,20-25% 4 PVNGS setpoints do not include margins for stem factor Strength & stem factor degradation,20% rate ofloading,10% diag- degradation. Setpoints are being adjusted to include a Weakness nostic inaccuracy and switch repeatability) to support margin for rate of loading effects. Setpoints already RFI 04.06.37 operability. Licensee also required that dp test results be include adjustments to compensate for diagnostic inaccu-analyzed to validate valve factor. This was noted by the racy and switch repeatability. Only failed dp test criteria NRC as a program strength. are reviewed against calculation assumptions. Licensee had not considered the effects of seismic 4 PVNGS calculations include the assumption that mini- RFI 04.06.08 dynamic loads in their calculations to determine required mum thrust / torque setpoints do not require an adjustment valve stem thrust. to compensate for the effects of a seismic event simulta-neous with MOV actuation. Licensee was unaware that Limitorque selection criteria 4 _Open Item. RF104.06.25 required motor starting torque for certain DC motors to be derated for ambient temperature exceeding 340R
PVNGS GL 89-10 MOY A3SESSMENT - ATTACHMENT "B" CROSS UTILITY REVIEW OF NRC GL 89-10 INSPECTION REPORTS NRC Inspection Report Comments Utility hlOV Assessment Remarks hlOV Inspectors emphasized the need to obtain test data from 4 PVNGS does not currently review design basis test data Weakness design basis testing to verify that the TOL sizing assurp- to confinn adequate TOL sizing. RFI 04.07.04 tions are appropriate for operation under both normal and design basis conditions. Inspectors noted that licensee used motor starting current 4,12 Open Item. RFI 04.06.20 or live times motor full load amps instead oflocked rotor RFI 04.06.21 current for degraded voltage conditions. Inspectors con- RFI 04.06.23 sider the use of any current less than locked rotor to be nonconservative. Ilowever the licensee used power fac-tors of 0.8 and 0.9 for 1800 rpm and 3600 rpm motors respectively compared with the les conservative industry value of 0.6. The licensee's use of conservative power factors and non-conservative motor starting current was identified as a follow up item. Inspectors stated licensee needs to review the power fac-tors assumed in the degraded voltage calculation relative I to the infonnation provided by Limitorque in its Update [ Letter 92-02. This was identified in the report as a con- , cern. Inspectors noted that licensee did not include a margin to account for tolerances in the bus undervoltage relay set-points in the degraded voltage calculations Although the work control process administratively 4 PVNGS evaluates dynamic test data within the schedule Weakness ensured that the dynamic test data was reviewed before requirements identified in 39DP-9ZZ01. However, evalu- RFI 04.06.09 i the equipment was returned to service, the inspector was ations and operability impact determinations are not nec-concerned that there was no specific timeframe for the essarily complete prior to restoration of operability. engineering review of the test data. Reliance on adminis-trative work controls to ensure data evaluation complete prior to return to service was considered a program weak-ness. 4 c., ,.,,,.,.,~_-3 1 - ,. . , , . , , , ,, ,
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PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B"
- CROSS UTILITY REVIEW OF NRC GL 39-10 BSPECTION REPORTS MOV NRC Inspection Report Comments Utility blOV Assessment Remarks ,
Inspectors noted that licensee did not consider valve 5 PVNGS thmst calculations include valve weak link val- Stremiti structural limits in the evaluation of MOV capability. ues. Inspectors noted that licensee measured strain gage 5 PVNGS measures stem tiuust and torque using strain Strength thrust, springpack displacement, motor current and gages where possible, and springpack displacement, switch actuations, and considered the licensee's diverse switches, and motor current. In addition, upstream and measurements to be a program strength. downstream pressure transducers are used where possi-ble. Inspectors noted that additional training may be war- 5,12 Open Item. RFI 04.11.10 ranted to minimize errors in the marking and evaluation of diagnostic traces, and in the recognition of trace anom-alics. Inspectors noted that no provisions had been established for refresher training on actuator maintenance or diagnos-tics. This was identified in the report as a concem. Inspectors noted that methods used of zeroing diagnostic 5 PVNGS procedure 39DP-9ZZ01 provides some guidance Strength & traces were not consistently applied. in the determination of trace zeroes, and 32MT-97256 Weakness provides direction for application of the " absolute zero" RFI 04.07.06 methodology with Movats equipment. Inspectors noted that the valves were not verified fully 5 PVNGS performs static strokes prior to dp strokes to Strength closed prior to the open stroke dp test. ensure diagnostics are functioning properly, and to verify proper position before dynamic testing. Inspectors noted that the torque switch repeatability eval- 5 PVNGS setpoint adjustments and dynamic test evalua- Strength . uation was either delayed or not addressed. tions include torque switch repeatability limitations as defined by Limitorque. Inspectors noted thrust calculations using tunning effi- 5 PVNGS typically uses pullout efficiency for open direc- RFI 04.05.07 ciency in the open direction, contrary to the recomenda- tion thrust calculations, but there are some exceptions. tions of Limitorque.
PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B" CROSS UTILITY REVIEW OF NRC GL 39-10 INSPECTION REPORTS NRC Inspection Report Comments Utility MOV MOV Assessment Remarks Assessment Inspectors noted that the observed packing load was not 5 Because PVNGS uses " Min Available" serpoints, varia- Strength & i factored into the licensee's thrust equation, tions in non-rotating stem packing load are not a critical Weakness factor in the thmst calculation. For rising rotating stem RFI 04.06.05 MOVs, packing load is torque and is compared with allowable values specified in the ICMODB to ensure that calculation assumptions are not violated. Ilowever, static data sheets for butterfly valves should be revised to ensure that running load torque is verified within the limits identified in the ICMODB notes. Inspectors informed the licensee that the assumptions 6, 8 PVNGS has not justified the assumptions used to account Weakness used to account for MOV degradation need to be justified for MOV degradation. ! RFI 04.06.11 before the scheduled completion date of the GL 89-10 program. NRC stated that stem lubrication degradation will be generically inspected at each site during closcout of GL 89-10 Phase 2 inspection. For evaluations of test data obtained at 80% of design 6,7 PVNGS has not addressed the need to perform multi- Weakness basis conditions, the licensee used straight line extrapola- point testing to collect data required to justify extrapola- RFI 04.07.01 tion to detennine output thrust at design basis dp.The lin- tion methods. ear extrapolation method was not verified by test data. To address this concem, licensee planned to perform multi-point dp tests on two valves, and the results of these tests will be applied to the rest of the MOVs, in conjunction with EPRI test results if available. Licensee was infonned that the assumptions used in the linear extrapolation methodology must be justified within the time limitations of GL 89-10. e w ....% . wgr 4, -- - ,r,. w. cr_.w,_, 7-.--,-.,,_ -wt+m.v,. ,,,v, - -,_-~<es.mm-v w ., .---- . - .,. -- r , ., ,,.-c , - - -.e , -
PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B" " CROSS UTILITY REVIEW OF NRC GL 89-10 INSPECTION REPORTS MOV NRC Inspection Report Comments Utility MOV Assessment Remarks inspectors noted as a program strength the establishment 7.11 PVNGS has established a similar testing sequence Strength of a rigorous testing sequence for each MOV, including including static as-found test, actuator refurbishment, i as-found static test, actuator refurbishment, dynamic test static as-left test, and dynamic tests. at reduced voltage, baseline static test, and an as-left static test. Inspectors considered the refurbistunent of MOVs prior to baseline and dp testing to be a program strength. The licensee was requested to identify all MOVs which 8 PVNGS has perfomied similar kinds of screens to deter- RFI 04.06.04 could be categorized as marginal and to reevaluate the mine marginal valves, but has not yet initiated design capability of those MOVs using supportable assumptions changes to improve MOV capability. and factors that account for all known sources of inaccu-racy. The licensee identified 69 MOVs that did not have at least a 15% design margin available above minimum thrust requirements. The 69 MOVs were reevaluated using less conservative criteria and were found to have sufficient capability to perform their safety function. The licensee subsequently identified modifications or other actions required to pennit the marginal MOVs to meet the standard design criteria. Implementation was scheduled to occur over the next two refueling outages. Inspectors considered the inability to generate a work his- 9 PVNGS SIMS system allows computerized retrieval of Strength tory sorted by valve tag number for the GL89-10 MOV MOV work histories. valves and the manual retrieval of work histories to be a weakness. Inspectors noted that the licensee revised plant hydro- 11 PVNGS dynamic test procedures that involve the use of a Weakness static test procedures to require post-test venting of the hydro pump need to be revised to include post-test vent- RFI 04.07.08 bonnets of any flex-wedge or double disc gate valves ing of the bonnets of any flex wedge or double disc gate used as hydrostatic test boundaries, valves used as test boundaries.
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PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT "B" CROSS UTILITY REVIEW OF NRC GL 89-10 INSPECTION REPORTS NRC Inspection Report Comments Utility MOV MOV Assessment Remarks Amum Licensee agreed to include a general definition and 1I PVNGS implementation plan and procedures do not Weakness description of the two-stage approach in the MOV pro- include a clear description of the two-stage approach that RFI 04.07.11 gram by April 1,1993. is in use. Licensee committed to evaluate impact of degraded volt- 11 PVNGS DC degraded voltage recalculation is not com- Weakness age conditions on DC powered stroke MOV stroke times. plete. RFI 04.06.22 Licensee agreed to develop a system to effectively track ii PVNGS formerly used the Llusiness Plan as a method for Weakness completion of all MOV program elements. prioritizing and tracking completion of GL 89-10 activi- RFI 04.02.01 ties. Use of the business plan has been discontinued, and a replacement method of prioritizing and tracking activity has not formally been implemented. The inspectors noted that the dynamic test procedures did 1I PVNGS dynamic test procedures are being revised to Strength not identify a differential pressure target value that the include target differential pressure values. testers should expect at the time the dynamic testing was perfonned. Since the principal intent of the testing is to demonstrate MOV operability at design basis dp, the inspectors consider that it is important to verify that acceptable pressures are achieved prior to testing. This was identified by the NRC as a concern.
- 1. Zion, Insp.12/14N2.
- 2. Clinton, Insp.1/14/93.
- 3. Davis Besse, insp 7/29/92
- 4. Trojan, Insp.~ 5/22B2
- 5. MUG Report of Region IV Part 2 Insp Results
- 6. Monticello, insp. 6/11/93
- 7. Wolf Creek, Insp. 5/7N3
- 8. Arkansas Nuclear One,Insp. 5/21/93
- 9. Comanche Peak, Insp. 3/1963
- 10. South Texas,Insp. 3/26/93
- 11. Fitzpatrick, Insp. 2/5/93
- 12. Watts Bar, Insp. 3/10/93 6
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-TQE ASSESSMENT NO 93-02 l GENERIC LETTER 89-10 .i MOTOR OPERATED VALVE PROGRAM ASSESSMENT :
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e GL 89-10 PROGRAMIC ASSESSMENT MOV SUBJECT INDEX , SCHEPULE LUDR4- DESIGN THERMAL TfiENDING TRAINING DEGRADED POST- DESIGN MOV SCtlNG CATlON &A52 OVER VOLTA 0E MAtNT. 8ASES & SWITCH REVIEW LOADS ENANCE TESTINO SETTING I' TESTINO 0442-01 04-0242 (C) 04-02-03 04-02 15 04-0217 (C) 04-03-03 (C) 04-02-06 tC) 04 0212 (C) 04 02-10(C) 0442-04 0442 09 (C) 04 02-05 04-05-05 04 05 03 04-02-18 04-0344 (C) 04 0310 (C) 04 0213 (C) 04-0211 (C) 04 02-07 04 02-23 (C) 04411 (C) 04-05-06 04-07 04 04-02 19 04-11 04 04410 rC) 04-02-14 (C) 04 0643 04 02-00 (C) 0448-01 (C) 04-0717 (C) 04 4 09 04-02-20 (C) 04-11 07 04-06-12 (C) 04 03-07 04-06-04 0443-01 04-10-02 04 03-11 (C) 04-07-28 04-02-21 (C) 04-11-08 04-0G 13 (C) 04 0348(C) 04-06 05 044342 04-10-03 (C) 04-07-33 04-02 22 (C) 04-11 10 04 4 14tC) 04-11 12 04-07 01 04 4 07 > 04-08-04 04-07 34 04-07-03 04-11-17 04-06-19 04-07-30 04 07 15 04 06-06 0447-14 04 07 41 04 09-01 04-11 19 04 4 20 04-07 31 04 07-16 0446-00 (C) 04407 (C) 04-0943 (C) 04-06-21 04-07-32 04-07-19 044615 (C) 04-09-04 04-06-22 04-07-35 04-07-20 (C) 04416 (C) t 04 09-05 04 06-23 04-07-36 04 07-21 04417 (C) i 04 06-24 04 07-37 04-07 22 04418 (C) , 04-06-26 04-07 39 (C) 04-07-23 04 & 25 04-07-09 04 07J0 04-07 24 (C) 04 4 29 044346 (C) 04-07-26 04 4 30 ! STRAIN VENDOR PRESSURE OL B9-10 LIMfTER CONFIO. 04-11-05 (C) 0446-31 (C) GAGES INFO LOCKINOt PROGRAM PLATES CON 7ROL 04 11 11 04 4 32 r THERMAL 04 07-10 04 06-33 (C) I BINDING 0447-27 (C) 0446-34 044345 (C) 04-0349 (C) 04-0%01 (C) 04-05-02 04 06-27 06 4 28 04 07 29 0446-35 (C) 04&O2 (C) 04-09 02 (C) 04-05-04 04-07-18 (C) 04 07 42 (C) 04436 (C) 1 0447-02 04-11 09 04-06-01 04-08-02 04 4 37 1 0447-25 04-0216 (C) 04-08-03 04 11-02 04438 (C) 04-08 05 (C) 04-11-03 04 4 39 04-06 06 04 0G 0446-40 QQ SCOPE 04-08-07 04-11 13 04 07-15 (C) OVERSITE 04 10-01 0411-14 (C) ',41115 04-02-24 04-07 11 04-11 18 04 11 16 041141 (C) 04 07-38 04-02-25 (C). Clomd as of 0917/93
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. : 'C' MOV ASSESSMENT TEAM e GENERIC LETTER 89-10 PROGRAMMATIC ASSESSMENT September 24,1993 @ 2:06 pm Page 1 -
Pvnes . CLOSED eT oOCvutwT MESPOseDEst? ftEQUEttOft. TAsar/ACT10el # OUESTIOM/ACTIOce (antAmt) COWP. ET D8.TEDUE CLO9E DATT 9teve Coppoch Chuela Pe!h 04.02.01 The APS Busireen Plan wee originapy good to IdumtfPy, eseign, p%riere, coordinate, and monMor progrees of OL 9410 activenee. The Businees Pten hos been @ecorenued and a repiecemeM eywom has not formePy tMMwe ernreemen%d. Current MOV pogram schedule only addreseos dynamic toedag med to add to the schedues evolustson and reeMon of test date including revision ef MOV calculesone, modeleesone of MOtre, em Aeston Cseeesry II The Mov Aseseement Team recernenende the 9Wlouring
- 1) Install and maintain a PC/9UN besarJ echedule management eyemm estely be the ces of Vehe Smeces Oroup under the
@ red control of the MOV program manager to identry, p torNm, coordinese and monitor progmes er sa OL esto acthees.
- 2) Evoluene overall schedule b determine W committnents b the NRC w4t be met. If not, provide revloed echadue w4th jusWIceUon b NRA for submMtal b the NRC, NOTE: PART t NOV INSPECTION ITEM fwA Hon Spencer 04 02 02 Page S, Secson 4 3 b of Part 1 inoperson (OL SS10l tie NRC Close& S. 9teur PWA 09/D1/93 recommende that APS tormeity accounts for tubriceBon degradefkm in setpoint contrais and enathodology. APS has no formal contml over Duplicare of 04 02 05 tubrication degradstlett NOTE: PART 1 NOV IISSPECTIO8e ITEM Mike Rednecle Scoe Bauer 04 02.03 Review of Design Beale CE pedomed design beele evaluenon. APS developed design bases mview peceowe (810P-4001Q anerwards. APS comm8tted to review the CE pressure, flow, and efverential pressure design input for en MOVs b verify compilaces with procedure APS awnmitted to review the CE preneure, Row, and differensel pesouro design input for all MOVt er eer9y compliance wMh the design beste review Piecedure 810P-40010 Acelem Casesory 11 NOTE: PART 1 RDOV peSMCTIOst ITEM Terry Lui Scott Bauer 04 02 04 Sisng MOVE and calculeeng 9pNeh Beeings . SIRC Sound smokeessee in the method for sesng MOVs and celeulesne e=Meh eatings Revised program leeued during the inspecean b address weaknesees Ache Cseasery 11 MOTE: PART 1 teOV Mt9PECTION ITYM
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!wa= cesesona Smo Rndoccie Chuck Reth 04.05 05 Veroy that the desion beefe m betuses a calculatism W worst cane 4m and dPhnentler geweeure Ibr the normal condPjone and the accident scenerlos doecdbed in applicable operaltng procedures.
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MOV ASCESSMENT TEAM GENERIC LETTER 89-10 PROGRAMMATIC ASSESSMENT
' September 24,1993 @ 2:06 pm Page 31 -
pwas Ct.ostoeyoOCom m ftESPost00tT fttout97084 TASM/ACTIOst # Out$flost/ ACTION (#10 ant') Comp.BT DAftDUt CtJOSE Daft Mike thouette Jim Young 04 Of 43 Oso to the eming et this asesserpent, fleed observasons d dynamic teseng wee nd practicabse since these tecs are typicepy perbreed dwing scheduled nduellrq outages. R le .-.. ..M end on independent tw observenen d dynernic treiing methodosogy and coeuns evehserien p e , CnDn evensmuon procenet to performed durmg the una t eq outage h addnion, thsid abeervenano should to perbrmed in ee erose d perindle meWeeence and perennnet training actMeen A sumelent appraisal er progrern enecevenes in these arene are not achiewd during the messesment eMee Ilmited hem resources were deh to these eroes cf review. Action Casseery N 9 tere C>psmek Etob Whiting 04Deof MOV ifSGAUW134 bas retcence k Cron 3-20548 Actbn 3 & 4 Cbeed: 8 Goeur N/A DEWt/n3 encommende thea vehe be n n __u bened upon prewbus ineonelverve deia. Ou ean erines, hee ew ==ive been pieced back into oupnce at 04 on 02 the 8410 er.+odule es incompsese or hee testing been seeened? m present any Ibnowup weting to tracked by Wsenen et a CAfs ocean m prenn at en unspoeined inner dem. Mike Rmet BobVWeng 04 Os 02 PM EQ Meir*mence Wern Teoks 047415 (Veno #037) and 048585 (VePro aonog as re%mnem Wawenance per 32MT422ae nearenced procedure according b DDC inden hee been cancened. Acteon Ceeeeery N A eeview of oil 8610 MOVs teoks should be made b verWy precedure werence
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-MOV ASOEISMENT TEAM
- GENERIC LETTER 89-10 PROGRAMMATIC ASSESSMENT ~ . -
September 24e 1993 @ 2:32 pm ' Page 39 i
' PVites ' . CLOSED BY DOCUEBEftf fat 9PO480 EDIT 91Ecuestoft TA9N/ACT10el # - QUESTIOtetACTIOtt ~ (MtAsst$ COesP.WT DAM DUE' C000 EDAM George Baumann Rye Spt*cer 04.11.17 1SDP4TT496 re8econces appendinee h 1SACCTR)1 wNch do not edet.
See Sec. 3 4 2 & 3.S S. A revtow et 150PETR98 le requested to ensure no other Worences do not exist. A pt change to lh 00 Of of ISOP-UTR88 to required to rosnovo et ref. 9e 15AC4TR01 Appendia U. Add correct procedure to ISOP4TRg8 which controls the 'Apperds C" As. - Ibbh Ditty, MeMenance Trebing Aseen Catenary N 9teve Coppock Fbn Spencer 0411.98 Dyneniac test date eveksellone pectanges developed in accordance with Cleesd: Ron Spencer 8WA cett3/93 as0P422nt end 7311e that are seed in evalueeng DP toegng en eeMy veisted vehoe are QA recorde end fe5 under the Opere8one QA Manuel, CROR 930710 treated to addrest %ck this leeue. 9ecten a 4. QA recordt V9E le not centroning to teet hatrucuan and See miso 04 08 OS. evalue8on packeGee se foguired tv ee Ope. QA Menuet Jim Minniche Fbn Spencer 0411.19 Appendia M et 1SDP4TR88, Page 2 of 2. Section 3 3 ausse that the t MOVATS Data Aequisition, signature and enefyve and accesocolse courses have course d's NYM08, NVM07. NVM11. Yet, these courses are not enptelped ender Sectan 4 TreHng couros descetpuan. Aino, Bec. 3 S ef Appenden M semase tied continued selected tralrung consiste of MOVATS 3000/3388 data acquisition, signedure oriefrels and emesesortes but, docent Det course d's R le not Itnowet what the quell 8tessen Intervals for conunued training are and what Wiey consist ef. i l, l r
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PVNGS MOV GL 89-10 ASSESSMENT is Test, Evaluation, and Rework Process For GL Static Test No Perform Static GL 89-10 Pregam Complete? Base 5ne Testing. ( Attachment F ) . ( Yes ir No Test Yes DlP Test Justify Not No Applicable 7 Practicable? Perfannmg Test as impracticable.
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Evaluate DIP Date- 4-- Perfonn DIP Test. < ir Are is 0lP Test Perfonn Test Results Valve M8 No Corrective Action Results y Review and Detennine Dperable? Acceptable? Operability impact. and!or initiate JCO. Yes Yes 3r Revise lCMODB- is 1( No / D!P Retest N Yes y,g,, Setpoints if < y,, Required. Operable 7 is No DfP Test Considered No I V e Design Basis Evaluate Phase 11 Data Corrective Action m Test? ir l'a ' and Review Operability endler initiate JCD.
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PVNGS GL 89-10 MOV ASSESSMENT - ATTACHMENT 'G" 1990 1991 1992 1993 1994 1995 l l l l l 1 1 I I I I I I I I I I I UNIT 1 1R4 S. T. ,1 R3- 1R5 m - STATIC - 1 TESTING :
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DYNAMIC # -' ' TESilNG ! 35 29 W W UNIT t DEADLINE UNIT 2 2R2 2R3 2R4 ENDOFCYCLE5 2RS NOUTAGE S u TIC -
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[///// SCHEDULED UNITOUTAGE SEMEMBM 8,1993
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PVNGS MOV GL-10 ASSESSMENT MOV DYNAMIC TESTING PERCENT COMPLETED 74%
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