ML20083R475

Interim Deficiency Rept DER 83-61 Re Failure of Ingersoll- Rand Low Pressure Safety Injection Pumps to Start.Initially Reported on 830914.Light Rubs for Lower Case Ring Determined Normal at 840309 Meeting.Final Rept by 840629

ML20083R475
Person / Time
Site:	Palo Verde
Issue date:	04/13/1984
From:	Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR
To:	Bishop T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
References
ANPP-29293-BSK, DER-83-61, NUDOCS 8404240159
Download: ML20083R475 (7)

Text

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Arizona Public Service Company April 13, 1984 ANPP-29293-BSK/TRB U. S. Nuclear Regulatory Conanission Region V Creekside Oaks Office Park i 1450 Maria Lane - Suite 210 i" Walnut Creek, CA 94596-5368 2 lq M Attention

Mr. T. W. Bishop, Director 2 ' ' '

p Division of Resident ,.

y "N Reactor Projects and Engineering Programs '

l e-

Subject:

Interim Report, Revision 1 - DER 83-61 r9 A 50.55(e) Potentially Reportable Deficiency Relating to Uni,t 1 LPSI Pumps Failed To Start And Do Not Produce The Required Head File: 84-019-026; D.4.33.2

Reference:

A) Telephone Conversation between P. Johnson and R. Tucker on l September 14, 1983 i

B) ANPP-28001, dated October 13, 1983 (Interim Report) q C) ANPP-28627, dated January 16, 1984 (Time Extension)

D) ANPP-28883, dated February 15, 1984 (Time Extension)

Dear Sir:

l The NRC was notified of a potentially reportable deficiency in Reference (A), an Interim Report was transmitted by Reference (B), and Time Extensions were requested by Reference (C) and (D). At that time, it was estimated that a Final Report would be available by April 17, 1984.

I Due to the extensive investigation and evaluation required, a revised Interim Report is attached. It is now expected that this information will be finalized by June 29, 1984, at which time a complete report will be submitted.

4 Very truly,yours

, / \

OUR 57h LLC E. E. Van Brunt, Jr.

APS Vice President, Nuclear ANPP Project Director j EEVB/TRE:ru Attachment cc: See Page Two M0 /P 29g\

Mr. T. W. Bishop DER 83-61 Page Two cc: Richard DeYoung, Director Office of Inspection and dnforcement U. S. Nuclear Regulatory Commission Washington, D. C. 20555 T. G. Woods, Jr.

W. E. Ide D. B. Fasnacht A. C. Rogers B. S. Kaplan L. A. Souza J. Vorees J. R. Bynum P. P. Klute A. C. Gehr W. J. Stubblefield W. G. Bingham R. L. Patterson R. W. Welcher H. D. Foster D. R. Hawkinson L. E. Vorderbrueggen G. A. Fiore111 S. R. Frost J. Self D. Canady Records Center Institute of Nuclear Power Operations 1100 Circle 75 Parkway, Suite 1500 Atlanta, CA 30339

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INTERIM REPORT - DER 83-61 POTENTIAL REPORTABLE DEFICIENCY ARIZONA PUBLIC SERVICE COMPANY (APS)

PVNGS UNITS 1, 2, & 3 I. Potential Problem The Low Pressure Safety Injection (LPSI) Pumps and the Containment Spray (CS) Pumps are supplied by Combustion Engineering (C-E) and are manufactured by Ingersoll-Rand (IR). The LPSI pumps are 8 x 20 type WDF and are driven by Westinghouse (W) 500 hp electric motors.

The CS pumps are 8 x 23 type WDF and are driven by Westinghouse (W) .

800 hp electric motors. Both pumps are similar in design (close-coupled to motors) and are identified by the following tag numbers:

LPSI S

_CS IMSIA-P01 IMSIA-P03 1MSIB-P01 IMSIB-P03 2MSIA-P01 2MSIA-P03 2MSIB-P01 2MSIB-P03 3MSIA-P01 3MSIA-P03 3MSIB-P01 3MSIB-P03 While performing preoperational testing at PVNGS Unit 1 on March 18, 1983, the LPSI pump, tag number IMSIB-P01 was run for arproximately three (3) minutes with the pump suction valve IPSIB-UV-652 closed. This was a violation of Preoperational Test Frocedure 91PE-1SIO8. A restart of the pump was attempted approximately three(3) hours later and the motor tripped ou'; on the time overcurrent protection circuit. The pump was disassembled and inspection revealed surface damage to the pump lower case wear ring-and mating surfaces of the impeller. This condition was reported on DER 83-21. The corrective action was to repair the rough surfaces by smoothing with a stoning operation. The pump was retested successfully at this time.

During the period of May 16 to May 19,1983, two (2) more failures to restart the LPSI pump occurred, due to the (W) motor time overcurrent trip. Disassembly and inspection revealed surface damage had occurred again on the case wear ring and impeller mating surfaces. As before, the corrective acton was to smooth the surfaces by the stoning operation.

Subsequently, this Deficiency Evaluation Report (DER 83-61) documented that on June 14, 1983, LPSI pump 1MS1BP01 again failed to restart during the continuation of the preoperational testing-after running for approximately twenty (20) minutes. This condition was investigated as an electrical problem, hence the LPSI Unit 1 (W) motor was replaced with a LPSI Unit 3 pump (W) motor, S/N 76F6057815079, by direction of APS.

Interim Report - DER 83-61 Page Two On June 19, 1983, the LPSI pump failed to restart again, after running successfully for two hours. On June 26, 1983, with the IR representative present, the pump was disassembled and inspected; the galling had occurred again. Under the IR representative's direction, the pump was reworked to smooth all galled areas and reassembled. Ten successful test starts were recorded on June 26.

On July 6,1983, the LPSI pump failed to restart.

On October 8,1983, the Unit 2 LFSI pump identified as tag number 2MSIA-P01 failed to restart after 41 successful starts and accumulation of 66 hours7.638889e-4 days <br />0.0183 hours <br />1.09127e-4 weeks <br />2.5113e-5 months <br /> of running time, this was documented on NCR SM-3026.

Nonconformance Reports SM-2756 and SM-2757 are also included in this Deficiency Evaluation Report (DER 83-61) to document that Unit 1 LPSI pumps IMSI AP01 and IMSIBP01 did not meet pump performance requirements for head pressure as specified in Purchase Order Specification 13-NM-001.

On December 3,1983, while ef fecting repairs to Unit 1 LPSI pump, tag number IMSIB-P02, the impeller from Unit 3 LPSI pump, tag number 3MSIA-P01, was removed for installation in LPSI Pump 1MSIB-P01 to replace the damaged Unit 1 LPSI pump impeller. During inspection of the Unit 3 impeller, it was revealed that impeller bore is out of tolerance per vendor drawing C-8X20A3DX1A. The bore should be 2.5005" + .0005". The actual bore measurement is from 2.5050" to 2.5015", this condition is documented on NCR SM-3418.

Due to the similarity of their design, the above reported deficient conditions on the LPSI pumps render the Containment Spray Pumps suspect also. There fore , the required corrective action will address both LPSI and CS pumps.

II. Approach To and Status of Proposed Resolution Upon recommendation by Combustion Engineering and Ingersoll-Rand and with Bechtel Engineering concurrence, the following corrective action plan has been implemented on the LPSI and CS pumps for Unit I and will be considered for Units 2 and 3. The attached Figure 1 represents a generic cross sectional view of the LPSI 8 x 20 and CS 8 x 23 WDF pumps, and is provided to identify by item number, corrective action modifications.

A. LPSI & CS

1. The upper and lower Monel K-500 case wear rings (Item 6) have been replaced with new rings using Armco Nitronic 60 material, which is known for its gall-resistant properties.

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I Interim Report - DER 83-61 Page TLree

2. To assure centralization of the upper case wear ring, the allowable run-out on the male rabbet of the stuffing box extension (Item 264) will be decreased from .005 inches to

.002 inches TIR. Location fits will also be doweled to limit movement after alignment is achieved.

3. The impeller (Item 3) ring fit areas have been serrated (grooved) to make this area less sensitive to any contact and to minimize loss of pump head due to increasing clearances between this area and the case wear rings. -

4. The running clearances between the impeller (Item 3) and casing rings (Item 6) on the LPSI pumps have been increased to .029" .036" diametrical. The running clearances between the impeller (Item 3) and the casing rings (Item 6) on the CS pumps will be .025" .032" diametrical.

5. The (W) motor bearings (not shown) will be inspected to ensure there will be no out-of-tolerance movement. The bearings may be replaced at the discretion of the vendor.

6. During testing of LPSI 1B with its 500 hp motor and with above Items 1-5 implemented, another failure'to start occurred on January 29, 1984. It was concluded that the shaft flexibility in combination with transient magnetic starting forces for thia particular motor, make it unsuited for reliable use with the WDF type pump.

7. An 800 hp containment spray pump motor from Unit 3 was installed on the LPSI 1B pump. The unit was operated for 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> to stabilize bearing temperatures. It was then started 5 times (20 minutes run time for the first four to satisfy motor cooling requirements). Subsequent disassembly and inspection revealed light contact at the lower impeller clearance (360*) with corresponding contact at approximately 270* of the lower case ring (on the side away from the pump discharge connection).

8. The pump was reassembled and 100 additional starts were made. All runs were approximately 20 minutes duration and at 2000 to 2100 gpm valve alignment. The first run (after refilling and venting) started at approximately 100 gpm thru the minimum flow line, same as above in Paragraph 7.

Subsequent disassembly and inspection (March 8, 1984) disclosed no evidence of contact at the upper ring clearance and no obvious additional contact at the lower ring clearance, as noted in Paragraph 7. The contact surfaces of the Nitronic 60 case rings were smooth with a light intermittent film transfer to the four impe11ers running surface lands.

l Interim Report - DER 83-61

- Page Four l

9. At a March 9,1984 meeting, APS, Bechtel, CE and IR agreed that the light rubs 'were normal and within acceptable '

limits. The ' significance of 'no evidence of contact on 90* of the lower case ring would indicate startup deflections are not resulting'in contact. The 270* contact probably resulted from the brief operation at minimum flow where pumps

' characteristically run rougher. _It was further agreed that this particular 800 hp. motor (frame 5809 with'6" diameter shaft): configuration has;been demonstrated to operate reliably in combination with the WDF type pumps.

10. 500 hp motors l(frame 5808 with 6" diameter shaft) are available and would also be reliable for use with the LPSI pumps based. on operating history with WDF type LPSI and CS pumps at the SONGS plant.

II. Projected Completion of Corrective Action and Submittal of the Final Report i

Evaluation of this condition and submittal of the Final Report is forecast to be completed by June 29, 1984.

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