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Category:DEFICIENCY REPORTS (PER 10CFR50.55E & PART 21)
MONTHYEARML20207M9231999-03-12012 March 1999 Amended Part 21 Rept Re Cooper-Bessemer Ksv EDG Power Piston Failure.Total of 198 or More Pistons Have Been Measured at Seven Different Sites.All Potentially Defective Pistons Have Been Removed from Svc Based on Encl Results ML18066A2771998-08-13013 August 1998 Part 21 Rept Re Deficiency in CE Current Screening Methodology for Determining Limiting Fuel Assembly for Detailed PWR thermal-hydraulic Sa.Evaluations Were Performed for Affected Plants to Determine Effect of Deficiency LD-97-033, Part 21 Rept Re Defect in Potter & Brumfield Mdr Relays, Models 170-1 & 7032.Extended Problem to Include All Mdr Relay Models W/Date Codes 93XX-95XX.Root Cause Analysis, Written Rept & Recommended Corrective Actions Due by 9712011997-11-20020 November 1997 Part 21 Rept Re Defect in Potter & Brumfield Mdr Relays, Models 170-1 & 7032.Extended Problem to Include All Mdr Relay Models W/Date Codes 93XX-95XX.Root Cause Analysis, Written Rept & Recommended Corrective Actions Due by 971201 LD-97-028, Part 21 Rept Re Contamination of Lubricant Which Has Led to Hardening of Lubricant in Certain Potter & Brumfield Mdr Relay Models 170-1 & 7032.Will Distribute Copy of Rept to Utils Having ABB-CE Designed Nuclear Steam Supply Sys1997-10-13013 October 1997 Part 21 Rept Re Contamination of Lubricant Which Has Led to Hardening of Lubricant in Certain Potter & Brumfield Mdr Relay Models 170-1 & 7032.Will Distribute Copy of Rept to Utils Having ABB-CE Designed Nuclear Steam Supply Sys LD-97-024, Part 21 Rept Re Error in Energy Redistribution Factor Used in LOCA Analysis for Listed Plants for Which ABB-CE Performed Analysis.Issued Recommendations Info Bulletin 97-0041997-08-14014 August 1997 Part 21 Rept Re Error in Energy Redistribution Factor Used in LOCA Analysis for Listed Plants for Which ABB-CE Performed Analysis.Issued Recommendations Info Bulletin 97-004 ML20140A9661997-05-29029 May 1997 Part 21 Rept Re Ksv Emergency Diesel Generator Power Piston Failure.Caused by Jacket Water in Combustion Chamber. Recommends That Users Verify That Crown Thickness at Valve Cutout Be 100 Minimum ML20137G6261997-03-25025 March 1997 Svcs Part 21 Rept Re Emergency Generators Installed at Zion Station Which Developed Significant Drop in Crankcase Lube Oil Level.Caused by Crack in Liner Wall,Allowing Jacket Water to Enter Chamber ML18065B0111996-10-18018 October 1996 Part 21 Rept Re Application of Certain Aspects of ABB-CE Safety Analysis Methodology ML20117G4641996-05-14014 May 1996 Part 21 Rept Re Cooper Bessemer Reciprocating Products,Div of Cooper Cameron Corp,Issued Ltr to Define Utils/Plants Containing Similar Equipment as Supplied on Cooper Bessemer Ksv & Enterprise Dsr EDGs LD-96-009, Part 21 Rept Re Potential Instrumentation Decalibr at Low Power.Affected Utils Should Ensure That Log Power Channels Properly Calibr & cross-correlated to Linear Power Channels at 100% Reactor Power1996-04-15015 April 1996 Part 21 Rept Re Potential Instrumentation Decalibr at Low Power.Affected Utils Should Ensure That Log Power Channels Properly Calibr & cross-correlated to Linear Power Channels at 100% Reactor Power ML20077D3431994-11-29029 November 1994 Part 21 Rept Re Suspect Master Connecting Rods & Contains Info Location in Engine for Rods ML20078G3051994-11-0909 November 1994 Rev to Part 21 Rept Re Potential Problem W/Master Power Connecting Rods.Vendor Recommends Listed Utils Perform Visual Insp of Master Rods to Determine Applicability of Rept LD-93-003, Part 21 Rept Re Defect in Potter & Brumfield Model 170-1 Relay.One of Two Rotor Return Springs Broke & Portion of Spring Lodged Between Rotor & Stator.Rotor Springs Supplied by Lewis Spring Co.Info Bulletin Being Prepared1993-01-13013 January 1993 Part 21 Rept Re Defect in Potter & Brumfield Model 170-1 Relay.One of Two Rotor Return Springs Broke & Portion of Spring Lodged Between Rotor & Stator.Rotor Springs Supplied by Lewis Spring Co.Info Bulletin Being Prepared ML20126J5961992-12-31031 December 1992 Part 21 Rept Re Potential Loss of RHR Cooling During Nozzle Dam Removal.Nozzle Dams May Create Trapped Air Column Behind Cold Leg Nozzle Dam.Mod to Nozzle Dams Currently Underway. Ltrs to Affected Utils Encl ML17306B0581992-10-0808 October 1992 Part 21 Rept Advising That Preliminary Evaluation of Rosemount Part 21 Notification Determined That Change in Systematic Static Pressure Span for Pressure Differential Transmitters May Result in Increase in Indicated Power ML17306A3341991-12-13013 December 1991 Followup Part 21 Rept Re Potential for Certain Westinghouse Products,Utilizing Dc Coil Assemblies,To Malfunction.Caused by Epoxy Compound Becoming semi-fluid During Svc.Initially Reported on 910624.Epoxy Check Will Be Incorporated ML20086P1591991-10-31031 October 1991 Part 21 Rept Re Microscopic Cracks in Fuel Nozzle Tip from Mfg Lot D87001.Cracks Perpendicular to Axis of Nozzle & Extend Through Case Hardening & Stop at Core.Interim/Final Report Will Be Forwarded as Further Development Occurs ML17305B6181991-06-24024 June 1991 Part 21 Rept Re Potential for Certain Westinghouse-supplied Products,Utilizing Dc Coil Assemblies,To Malfunction. Initially Reported on 910620.Recommends That All Suspect Devices Be Replaced & Epoxy Compound Probed ML17348A1621990-03-27027 March 1990 Part 21 Rept Re Matls W/Programmatic Defects Supplied by Dubose Steel,Inc.Customers,Purchase Order,Items & Affected Heat Numbers Listed ML17223A7451990-01-26026 January 1990 Part 21 Rept Re Backup Rings Furnished in Spare Parts Seal Kits & in 25 Gpm 4 Way Valves as Part of Actuators Made of Incorrect Matl.Rings Should Be Viton & Have Been Identified as Buna N ML17304B1281989-04-20020 April 1989 Part 21 Rept Re Multiple Control Element Assembly Slip or Drop Events at Unit 1 on 881210.Caused by Intermittent T Grounding of Control Element Drive.Initially Reported on 890419.Stack Assemblies Will Be Replaced ML20247P7991989-04-0404 April 1989 Part 21 Rept Re Atmospheric Dump Valves.Cause of Failure Speculative But Result of Piston Ring That Failed to Seal. Resolution to Problem Requires Increasing Pilot Valve Capacity & Reworking of Plug to Enlarge Pilot Flow Area ML17304B1691989-02-0202 February 1989 Part 21 Rept Re Ruskin Div Supplied Dampers W/Itt Actuators. Div Currently Evaluating Loctite Compound Which May Be Applied,Following Verification of Proper Damper Adjustment, to Threads of Extension Shaft in Place ML17304A9711989-01-18018 January 1989 Part 21 Rept Re Ksv Standby Diesel Generator Rocker Arm Failure.On 890104,exhaust Valve Rocker Arm Installed in KSV-20-T Engine Broke at Plant.Investigation Revealed That Castings Cracked During Mfg.Review Underway ML20207P0151988-10-0404 October 1988 Part 21 Rept Re Fuel Nozzle Tips in Standby Diesel Generator KSV-20-T W/Cracks Permitting Diesel Fuel to Be Sprayed Into Cylinders.Heavy Vapors Observed Emitting from Breathers on Some Cylinder Heads ML20153B2811988-02-22022 February 1988 Part 21 Rept Re Defect in Operation of Gas Monitors Using Fixed Filters.Initially Reported on 880212.Caused by Error in Software for Monitors.Vendor Testing Mod to Software & in Interim Recommends Changing Filters Every 48 H ML17303A6081987-10-0202 October 1987 Part 21 Rept Re Fasteners Installed in motor-operated Valves.Initially Reported on 870930.Valve yoke-to-yoke Adapter Fasteners Replaced to Meet Allowable Stress Limits ML17303A5231987-07-17017 July 1987 Final Part 21 Rept RER-QSE 87-12 Re Improper Application of Agastat Relay.Initially Reported on 870714.Relay Contacts Burnished.Design Change Implemented to Replace Relays W/ Hermetically Sealed Relay W/Bifurcated Contacts ML17300A7791987-04-13013 April 1987 Revised Deficiency Evaluation Repts DER 84-30 & 86-25 Re U-2 Diesel Generator Valves & Kaman Radiation Monitors, Respectively.Changes to Reported Info or Corrective Actions Noted ML20205P7771987-03-19019 March 1987 Rev 3 to Final Part 21 & Deficiency Rept DER 82-46 Re Itt Barton Pressure Transmitters Supplied by C-E That Do Not Meet Overpressure Requirements.Rev Updates & Clarifies Info Re Description of Deficiency & Corrective Actions ML20205P9241987-03-19019 March 1987 Part 21 & Rev 2 to Final Deficiency Rept DER 84-08 Re Itt Barton Model 763 Transmitters Supplied by C-E Having Output Errors of -2 to -3% of Calibr Span.Defects May Affect Monitoring & Alarm Capabilities of Shutdown Cooling Sys ML20207S8341987-03-0606 March 1987 Final Part 21 & Deficiency Rept RER-GSE 86-41 Re Control of Design Change Packages (Dcp).Initially Reported on 861205. Review & Correction of DCPs Will Be Completed by 870101. Conditions Not Reportable Per 10CFR50.55 & Part 21 ML20207S6981987-03-0505 March 1987 Final Part 21 & Deficiency Rept RER-QSE 87-05 Re Travel Limit Switches on HVAC Dampers.Initially Reported on 870217. Condition Not Reportable Per 10CFR21 & 50.55 ML20207S9861987-03-0505 March 1987 Part 21 & Deficiency Rept RER-QSE 87-08 Re Lead Wires on Limitorque Operators.Initially Reported on 870217.Condition Found Not Reportable Under 10CFR50.55(e) & 10CFR21 ML17300A6741987-02-27027 February 1987 Part 21 & Final Deficiency Rept DER 86-29 Re Crack in Letdown HX Nozzle Mfg by Richmond Engineering Co & Supplied by C-E.Initially Reported on 861114.Nozzle Crack Initially Weld Repaired Under Nonconformance Rept Ncr NA-1942 ML20207R0951987-02-23023 February 1987 Deficiency Rept DER 86-29 Re Letdown HX Nozzle Crack. Initially Reported on 861114.Due to Extensive Investigation, Time Extension Requested.Final Rept Expected by 870227 ML20212D8301987-02-12012 February 1987 Deficiency Rept DER 86-29 Re Letdown HX Nozzle Crack. Initially Reported on 861114.Due to Extensive Investigation, More Time Required for Final Rept.Rept Anticipated by 870223 ML20211Q2681987-02-0909 February 1987 Final Part 21 & Deficiency Rept RER-QSE 86-47 Re Failure of Unit 3 B Diesel Generator Engine.Initially Reported on 861223.Units 2 & 3 Cylinder Master Rods Replaced.All Diesel 3A & Remaining 3B Rods Ultrasonically Examined ML20211A2101987-01-29029 January 1987 Final Part 21 & Deficiency Rept DER 86-32 Re Discrepancies Between Pipe Support Designs & Stress Calculations.Initially Reported on 861231.Caused by Personnel Design Errors. Condition Not Reportable Per 10CFR50.55(e) & 10CFR21 ML20211A6951987-01-23023 January 1987 Interim Deficiency Rept DER 86-30 Re Unqualified Fuses, Terminal Blocks & Wires.Initially Reported on 861104.Due to Extensive Investigation & Evaluation Required to Address Issue,Final Rept Expected by 870219 ML20213A0711987-01-20020 January 1987 Final Part 21 & Deficiency Rept RER-QSE 87-01 Re Brown Boveri K600/K800 Circuit Breakers W/Possible Cut Wires on Wire Harness.Initially Reported on 860630.Gear Guards Will Be Installed to Protect Circuit Breakers During Next Outage ML20212Q1231987-01-13013 January 1987 Part 21 & Updated Interim Deficiency Rept RER-QSE 86-47 Re Diesel Engine Generator Failure.Initially Reported on 861223.Iron Plated Rod Previously Identified as 6 Should Be Rod 9.Final Rept Will Be Submitted by 870220 ML20212H5451987-01-12012 January 1987 Part 21 Rept Re Break of Master Power Rod at Fractured Surface.Caused by Fatigue Failure Originating in Rod When Iron Plating in Articulated Rod Pin Bore Failed,Resulting in Engine Inoperability.Rod Replaced ML20212R3301987-01-0909 January 1987 Interim Deficiency Rept DER 86-29 Re Letdown HX Nozzle Crack.Initially Reported on 861114.Due to Extensive Investigation & Evaluation Required to Address Complexity of Issue,Next Rept Delayed Until 870216 ML20212Q1711987-01-0909 January 1987 Part 21 & Interim Deficiency Rept RER-QSE 86-47 Re Diesel Generator Engine Failure.Initially Reported on 861223.Caused by Fatigue Failure of Main Connecting Rod 9 Due to Addition of Iron.Final Rept Will Be Submitted by 870220 ML20210A9191987-01-0707 January 1987 Rev 1 to Final Part 21 & Deficiency Rept DER 85-38 Re QA Audit at Ge.Initially Reported on 851108.Re-audit at GE Identified Addl Purchase Orders Requiring Review for Validity of Proper Certification ML20207M2561987-01-0202 January 1987 Interim Deficiency Rept DER 86-31 Re Loose Windings of Diesel Generator.Initially Reported on 861205.Defective Rotor Removed & Visually Inspected by Vendor.Pole Piece Fasteners re-torqued.Final Rept Delayed Until 870209 ML20207M6541987-01-0202 January 1987 Interim Deficiency Rept RER-QSE 86-41 Re Withdrawal of Limitorque Operators from Warehouse W/O Required Design Changes.Initially Reported on 861205.Operators Located & Procedures Reviewed.Next Rept Delayed Until 870306 ML20207C5661986-12-12012 December 1986 Rev 2 to Deficiency Rept DER 86-04 Re Certain Seals Not Properly Supported & Rev 19 to DER 86-19 Re Modules Returned to Ga/Sorrento Electronics.Summary Description & Evaluation of Impact Encl ML20215E3691986-12-0505 December 1986 Interim Deficiency Rept DER 86-29 Re Letdown HX Nozzle Crack.Initially Reported on 861114.Due to Extensive Investigation & Evaluation,Final Rept Delayed Until 870115 1999-03-12
[Table view] Category:TEXT-SAFETY REPORT
MONTHYEARML17300B3811999-09-30030 September 1999 Monthly Operating Repts for Sept 1999 for Pvngs,Units 1,2 & 3.With 991007 Ltr ML17300B3271999-08-31031 August 1999 Monthly Operating Rept for Aug 1999 for Pvngs,Units 1,2 & 3 ML17313B0751999-08-27027 August 1999 LER 99-002-00:on 990730,test Mode Trip Bypass for EDG Output Breakers Not Surveilled.Cause Under Investigation.Operations Personnel Conservatively Invoked SR 3.0.3 for SR 3.8.1.13. with 990827 Ltr ML17313B0611999-07-31031 July 1999 Monthly Operating Repts for July 1999 for Pvngs,Units 1,2 & 3.With 990810 Ltr ML17313B0191999-07-16016 July 1999 LER 99-005-00:on 990618,RT on Low DNBR Was Noted.Caused by Hardware Induced Calculation Error.Cr Operator Was Taken to Place Reactor in Stable Condition IAW Appropriate Operating Procedure ML17300B3151999-06-30030 June 1999 Monthly Operating Repts for June 1999 for Pvngs,Units 1,2 & 3.With 990714 Ltr ML17313A9921999-06-21021 June 1999 Special Rept:On 990525,RMS mini-computer Was Removed from Service to Implement Yr 2000 Mod & Was OOS Longer than 72 H Allowed.Caused by Planned Y2K Mods.Preplanned Alternate Sampling Program Was Initiated ML17313A9911999-06-18018 June 1999 Special Rept:On 990510,loose-part Detection Sys Channel 2 Was Declared Inoperable.Caused by Malfunction of Mineral Cable Connector to Accelerometer.Licensee Will Implement Modifications Which Will Enhance loose-part Detection Sys ML17313A9731999-05-31031 May 1999 Monthly Operating Repts for May 1999 for Pvngs,Units 1,2 & 3.With 990608 Ltr ML17313A9281999-05-0707 May 1999 LER 99-004-00:on 990408,PSV Lift Pressures Were Outside of TS Limits.Caused by Lift Pressure Setpoint Drift.Psvs Have Been Tested,Disassembled,Inspected,Reassembled & Certified at Wyle Labs ML17313A9201999-04-30030 April 1999 Monthly Operating Repts for Apr 1999 for Pvngs,Units 1,2 & 3.With 990512 Ltr ML17313A8951999-04-14014 April 1999 LER 99-003-00:on 990317,required Surveillance Requirement Not Completed Due to Deficient Procedure,Was Determined. Caused by Cognitive Personnel Error.St Procedures Revised to Require Chiller to Be Operating & Oil Temperature Checked ML17313A8921999-04-13013 April 1999 LER 98-003-01:on 980902,discovered That MSSV as-found Lift Pressures Were Outside TS Limits.Caused by Bonding of Valve Disc to Nozzle Seat.Affected Valves Were Adjusted,Retested & Returned to Svc ML17313A8891999-04-0909 April 1999 LER 99-001-00:on 990310,RT on High Pressurizer Pressure Was Noted.Caused by Loss of Heat Removal.Cr Supervisor Was Removed from Shift Duties for Diagnostics Skills Training. with 990409 Ltr ML17300B3071999-03-31031 March 1999 Seismic Portion of Submittal-Only Screening Review of Palo Verde Nuclear Generating Station Units Ipeee. ML17313A8801999-03-31031 March 1999 Monthly Operating Repts for Mar 1999 for Pvngs,Units 1,2 & 3.With 990412 Ltr ML20207M9231999-03-12012 March 1999 Amended Part 21 Rept Re Cooper-Bessemer Ksv EDG Power Piston Failure.Total of 198 or More Pistons Have Been Measured at Seven Different Sites.All Potentially Defective Pistons Have Been Removed from Svc Based on Encl Results ML20207H7471999-03-10010 March 1999 1999 Emergency Preparedness Exercise 99-E-AEV-03003 ML17313A8361999-03-0101 March 1999 LER 99-001-00:on 990103,TS Violation for Power Dependent Insertion Limit Alarm Being Inoperable.Caused by Personnel Error.Revised Procedure to Clarify How Computer Point Is to Be Returned to Scan Mode.With 990302 Ltr ML17313A8501999-02-28028 February 1999 Monthly Operating Repts for Feb 1999 for Palo Verde Nuclear Generating Station.With 990311 Ltr ML17313A7791999-02-0505 February 1999 Safety Evaluation Accepting Licensee Rev to Emergency Plan That Would Result in Two Less Radiation Protection Positions Immediatelu Available During Emergencies ML17313A8061999-01-31031 January 1999 Monthly Operating Repts for Jan 1999 for Pvngs,Units 1,2 & 3.With 990218 Ltr ML17313A7701999-01-15015 January 1999 LER 96-008-00:on 960507,inadequate Procedure Results in Nuclear Power Channels Not Calibrated During Power Ascension Tests Occurred.Caused by Deficient Procedure.Procedure Revised ML17313A7381998-12-31031 December 1998 Monthly Operating Repts for Dec 1998 for Palo Verde Nuclear Generating Station,Units 1,2 & 3.With 990113 Ltr ML20206H2101998-12-31031 December 1998 SCE 1998 Annual Rept ML17313A7031998-11-30030 November 1998 Monthly Operating Repts for Nov 1998 for Pvngs,Unit 1,2 & 3. with 981209 Ltr ML17313A6701998-11-0404 November 1998 Rev 2 to PVNGS Unit 2 Colr. ML17313A6741998-10-31031 October 1998 Monthly Operating Repts for Oct 1998 for Pvngs,Units 1,2 & 3.With 981109 Ltr ML17313A6611998-10-24024 October 1998 LER 98-008-00:on 980729,EQ of Electrical Connectors Were Not Adequately Demonstrated.Caused Because Test Was Conducted with Only Single Lv Connector & Without Fully Ranged Inputs. Revised EQ Requirements ML17313A6561998-09-30030 September 1998 Monthly Operating Rept for Sept 1998 for PVNGS Units 1,2 & 3.With 981007 Ltr ML17313A5961998-09-14014 September 1998 LER 98-002-00:on 980814,B Train H Recombiner Was Noted Inoperable Due to cross-wired Power Receptacle.Cause of Event Is Under investigation.Cross-wired Power Supply Receptacle for B Train H Recombiner Was re-wired ML17313A5761998-09-0808 September 1998 LER 98-003-01:on 980113,discovered That One Channel of RWT Level Sys Had Failed High.Caused by Water Intrusion Into Electrical Termination Pull Box.Weep Holes Were Drilled Into Bottoms of Pull Boxes Nearest Level Transmitters ML17313A5591998-08-28028 August 1998 LER 98-001-00:on 980730,entered TS 3.0.3 Due to Safety Injection Flow Instruments Being Removed from Svc.Caused by Personnel Error.Transmitters Were Unisolated & Returned to svc.W/980828 Ltr ML20151S0941998-08-21021 August 1998 Rev 6 to COLR for PVNGS Unit 3 ML20151S0861998-08-21021 August 1998 Rev 4 to COLR for PVNGS Unit 1 ML20151S0901998-08-21021 August 1998 Rev 1 to COLR for PVNGS Unit 2 ML18066A2771998-08-13013 August 1998 Part 21 Rept Re Deficiency in CE Current Screening Methodology for Determining Limiting Fuel Assembly for Detailed PWR thermal-hydraulic Sa.Evaluations Were Performed for Affected Plants to Determine Effect of Deficiency ML17313A5401998-08-13013 August 1998 Special Rept:On 980715,declared PASS Inoperable.Caused by Failure of Offgas Flush/Purge Control Handswitch HS0101. Handswitch Replaced & Post Maintenance Retesting Was Initiated ML17313A5301998-07-31031 July 1998 Monthly Operating Repts for July 1998 for Pvgns,Units 1,2 & 3.W/980812 Ltr ML17313A5201998-07-30030 July 1998 LER 98-004-00:on 980630,personnel Discovered That Pressure Safety Valve Had Not Received Periodic Set Pressure Test for ASME Class 1 Pressure Safety Valve.Caused by Personnel Error.Pressure Safety Valve reviewed.W/980730 Ltr ML17313A5791998-07-0707 July 1998 to PVNGS SG Tube ISI Results for Seventh Refueling Outage Mar & Apr 1998. ML17313A5001998-06-30030 June 1998 Monthly Operating Repts for June 1998 for Palo Verde Nuclear Generating Station,Units 1,2 & 3.W/980710 Ltr ML17313A4671998-06-19019 June 1998 LER 98-007-00:on 980520,CR Personnel Observed Flow & Pressure Perturbations on Chemical & Vol Control Sys Letdown Sys.Caused by Cyclic Fatigue Due to Dynamic Pressure Transients.Unit Letdown Piping Replaced ML17313A4521998-06-19019 June 1998 Rev 5 to COLR for Pvngs,Unit 3. ML17313A4501998-06-19019 June 1998 Rev 4 to COLR for Pvngs,Unit 3. ML17313A4131998-06-0505 June 1998 LER 98-006-00:on 980507,determined That Plant Was Outside Design Basis Due to SI Discharge Check Valve Reverse Flow. Check Valve Was Disassembled,Examined & Reassembled, Whereupon Valve Met Acceptance Criteria ML17313A4211998-05-31031 May 1998 Monthly Operating Repts for May 1998 for Pvngs,Units 1,2 & 3.W/980609 Ltr ML17313A3951998-05-26026 May 1998 LER 98-005-00:on 980428,noted That Required Response Time Testing Had Not Been Performed.Caused by Personnel Error. Coached I&C Personnel Responsible for Reviewing Work Authorization Documentation ML17313A3691998-04-30030 April 1998 Monthly Operating Repts for Apr 1998 for PVNGS.W/980412 Ltr ML17313A3251998-04-0101 April 1998 LER 98-004-00:on 980304,safety Valves as-found Pressures Out of Tolerance.Cause of Event Is Under Investigation.Three Mssv'S & Psv Will Be Replaced W/Refurbished & Recertified Valves During Refueling Outage U1R7 1999-09-30
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4 1
- ' 0a- 50 Arizona Nuclear Pcwer Project P.O. BOX 52034
- PHOENIX. ARIZONA 85072-2034 . . . _LJ J W l5 l.7 g -
r January 11, 1984 , , .
ANPP-31676-TDS/TRB " '?O1 U. S. Nuclear Regulatory Commission Region V 1450 Maria Lane - Suite 210 Walnut Creek, CA 94596-5368 Attention: Mr. D. F. Kirsch, Acting Director Division of Reactor Safety and Projects
Subject:
Final Report, Revision 1 - DER 83-61 A 50.55(e) Reportable Condition Relating to LPSI Pumps Failure 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 September 14, 1983 B) ANPP-28001, dated October 13, 1983 (Interim Report)
C) ANPP-28627, dated January 16,1984 (Time Extension)
D) ANPP-28883, dated February 15, 1984 (Time Extension)
E) ANPP-29293, dated April 13, 1984 (Interim Report)
F) ANPP-29841, dated June 27, 1984 (Time Extension)
G) ANPP-30134, dated August 9, 1984~(Final Report)
Dear Sir:
Attached is Revision 1 of our final written report of the Reportable Deficiency under 20CFR50.55(e), referenced above. .This revision clarifies the Condition Description and provides updated information on.
the Corrective Action which has been taken.
Very truly you ,
EP. cut E. E. Van Brunt, Jr.
nJ H APS Vice President Nuclear Production ANPP Project-Director EEVB/TRB:nj 4
Attachment:
cc: See Page Two 8501240627 840111 i PDR ADOCK 05000528 S pyg .
1 e R'd 7
l' Mr. D. F. Kirsch DER 83-61 j Page Two ec: Richard DeYoung, Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission-Washington, D. C. 20555 T. G.. Woods, Jr. I D. B. Karner (
W. E. Ide l D.-B. Fasnacht A. C. Rogers L. A. Souza D. E. Fowler i T. D. Shriver C. N.-Russo J. D. Houchen J. R. Bynum J. M. Allen A. C. Gehr W. J. Stubblefield W. G. Bingham R. L. Patterson.
.R. W. Welcher H. D. Foster D. R.' Hawkinson R. P. Zimmerman M. Matt T. J. Bloom D. N. Stover L. Clyde-D. Canady J. E. Kirby Records Center Institute of Nuclear Power. Operations 1100 circle 75 Parkway, Suite 1500 Atlanta, GA 30339 Mr. E. Licitra U. S. Nuclear Regulatory Commission Phillips-Building 7920 Norfolk Avenue Bethesda, MD 20814
'i FINAL REPORT - DER 83-61 DEFICIENCY EVALUATION 50.55(e).
-ARIZONA PUBLIC SERVICE COMPANY (APS)
PVNGS UNITS 1, ?> 3 t
I. Description of Deficiency The-Low Pressure Safety Injection (LPSI) Pumps are supplied by Combustion Engineering (C-E) and are manufactured'by JIngersoll-Rand-(LR) and include 500 hp Westinghouse motors.
4 . They are identified by tag numbers as follows:
4 1MSIA-P01' 2MSIA-P01 3MSIA-P01.
JMSIB-P01- 2MSIB-P01 3MSIB-P01 While performing preoperational' testing at Unit-1 on.
March 18, 1983, LPSI pump JMSIB-P01 was run for approximately three minutes with the pump suction valve IPSIB-UV-652 closed. A restart of the pump was attempted approximately three hours later and the motor failed to start (i.e., tripped out on the time overcurrent protection circuit which was set
- 'at 6 seconds). The pump was disassembled and inspection revealed surface damage (galling) to the pump lower case wear ring and mating surfaces or the impeller. Also, the lower-case ring was angularly displaced approximately 3/4". This incident was the subject of DER 83-21. The corrective action was to repair the rough surfaces by smoothing with a stoning operation and replace the lower case ring set screws.. The j' pump was then retested successfully.
-During the period of May 16 to May 19, 1983, two (2) more failures to start the same LPSI pump occurred due to motor.
l time overcurrent trips. -Disassembly and inspection revealed galling had_ occurred again on the lower case year ring and impeller mating surfaces and the lower case ring was angularly
, displaced approximately 3/4". As before,.the corrective action was to smooth the impeller and case ring by stoning.
Subsequently, this DER (83-61) documented that on June 14, 1983, LPSI pump 1MSIB-P01 again failed to start i during the continuation of the preoperational testing a'ter ,
running ' for approximately , twenty minutes. At this point, the l condition was attributed to a motor problem due to the fact i that after each failed start, :the pump was free to turn but i was not coming to speed. Therefore, the LPSI Unit 1 motor was ,
replaced with a Unit 3 LPSI pump motor.
On June 19, 1983, the same LPSI pump with the Unit 3 motor i
failed to start after running successfully for two bours. On !
June 21, 1983,- with the'IR representative present, the pump was' disassembled and inspected. Galling of the lower' ring surfaces had occurred again and the lower case ring was
< angularly displaced approximately 3/4".
, l
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ , . _ _ . _ . __ - , . . , ,. _ _ ..m . __ . _ , _ -_ - . ,
. . - - - - ,.~. . -. . _ . . .. --
1 <
, J #,C ,
Mr. D. F. Kirsch '
ANPP-31676' Page Two
-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 6,71983, the LPSI pump again' failed Lto start.
L On October 8,1983, Unit 2 LPSI pump 2MSIA-P01 failed to start (6-second overcurrent trip) after 41 succcessful 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, reference
' NCR SM-3026. Disassembly revealed heavy galling at the lower impeller to case ring fit and the lower case ring was angularly displaced approximately 3/4", the same as observed after the Unit 1 pump failures to start.
~ Miscellaneous
- 1. NCRs SM-2756 and SM-2757 are also included in this DER (83-61) to document.that test data indicated pumps 1MSIA-P01 and IMSIB-P01 did not meet performance requirements for head-capacity (Ref. CESSAR Table 6.3.2-1)..
f 2. On December 3,1983, the impeller from LPSI pump 3MSIA-P01 was removed for installation in LPSI pump IMSIB-P01 to replace the damaged Unit 1 impeller. During inspection of the Unit 3 impeller, it was noted that the bore was out of tolerance per vendor drawing C-8X20A3DX1A. The bore should be 2.5005"+.0005". The actual bore measurement is 2.5050" L to 2.5015" (Ref. NCR SM-3418). All other LPSI pump impe11er bores were within tolerance.
- 3. Inspection rf running clearances on pump IMSIB-P01 on January 24, 1984~ after test runs to evaluate a preloaded bottom bearing and modified running clearances with Nitronic 60 case rings, revealed ~1ight contact (Ref. NCR-SM-3588),
Equipment Description The LPSI pumps are 8 x 20 type WDF which are single-6. age, i
centrifugal, vertical, overhung, end-suction type, j close-coupled'to Westinghouse frame 5010,. vertical solid shaft i (VSS) 500 hp, 1780 1qps 3/60/4000, squirrel cate induction i- motors.
The Containment Spra'y (CS) pumps are IR 8 x 23 type WDF which l- have a 23" diameter: impeller with matching diffuser fitted-
- into the' esse 8 X 20 WDF casing as'the LPSI pumps. The 23"'
l impe11ers are optimized for a different head-capacity range than the LPSI pumps which have 20" diameter impe11ers and-Jarger diameter case ring fits.
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ANPP-31676~
Page Three
. The motors are Westinghouse'frase 5809, VSS, 800 hp, 1780 rps, 3/60/4000, squirrel case induction type, with the same upper and lower bearings, mounting fit to pump, and shaft extension dimensions as the LPSI pump motors. The CS ~p ump / motor sets
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are . supplied by C-E and are identified by tag numbers as follows:
IMSIA-P03 2MSIA-P03 3SMIA-P03 '
IMSIB-P03 2MSIB-P03 3SMIB-P03
.Because of the design similarities between the LPSI and CS pumps, the corrective actions address both LPSI and CS pumps, >
even though CS pumps have never failed' to. start.- i 4
II. Analysis of Safety Implications i
The Low Pressure Safety Injection (LPSI) pumps are used to provide core cooling flow in a shutdown cooling mode and also to provide emergency core cooling flow if there is a Loss of j Cooling Accident (LOCA). 6 The Containment Spray (CS) pumps are designed to remove Lest from the containment atmosphere in the event of a LOCA. They are also used to circulate reactor coolant to remove decay heat following plant shutdown.
- Based upon the above, the failure to start condition is ;
evaluated as reportable under the -requirements of 10 CFR
~
Part 50.55(e) since, if left uncorrected, it could adversely.
affect the safety of plant operations.
- Also, this condition is evaluated as reportable under the requiremente of 10CFR Part 21:since it constitutes a substantial safety hazard and, if left uncorrected, could adversely affect the capability to safely' shutdown the reactor.
III.A. Corrective Actions, LPSI and CS Pumps The cause of the failure to start was theorized to be hard t contact between the impeller and the lower case ring.
Accordingly, based on the recoseendation of'Coahustion ,
Engineering and Ingersoll-Rand'(Ref., 10 & 11)~and with Bechtel Engineering concurrence,;the following modifications were -implemented on the LPSI'and CS pumps for Units 1, 2, and 3'to.sitisate the' effects of the contact. These modifications
[ were accomplished in accordance with NCR SM-2156 for the Unit 1 LPSI pumps and DCPa ~ 2SM-SI-115'and 3CM-SI-115 for the Units
~
2'& 3.LPSI' pumps and DCPs ISM-SI-114, 2SM-SI-114, and
.MCM-SI-114 for the CS pumps.
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ANPP-31676-Page.Four Figure 1 attached, represents a generic cross sectional view
' of the LPSI 8 X 20 and CS X 23 WDF pumps, and is provided to identify, by ites number, the corrective action modifications.
- 1. The upper and lower K-500 Monel case-wear rings (Item 6) were replaced with new rings using Arsco Nitronic 60 material which is known for its gall-resistant properties (Ref. 1). The Nitronic 60 is more gall-resistant than K-M>nel and has a lower coefficient of friction. l
- 2. (a) The running clearances between the impeller (Ites 3) and casing rings (Item 6) on the LPSI pumps were increased to .029" .036" diametrical, (Ref. 2, Item 3). This was I
done to reduce startup contact friction forces.
(b) The running clearances between the impeller (Item 3) and the casing rings (Ites 6) on the CS pumps were increased to .025" .032" diametrical (Ref. 3), for the same reason as 2(a).
- 3. The impeller (Ites 3) upper and lower ring fit areas were serrated (grooved) to make them less sensitive to any contact and to minimize possible loss of pump head due to increasing the running clearances (Ref. 2, Item 4).
- 4. To more accurately assure centralization of the impeller in the case rings and to exclude a stackup of tolerances as a factor in the LPSI pump failure to start investigation, run-outs on the upper and lower sale rabbat fits of the stuffing box extension (Item 264) were decreased from .005" to .002" total indicated reading (TIR). Also, the run-out of the support head to motor fit was reduced from .004" to
.002" TIR and this fit doweled to limit movement after final alignment (Ref. 2, Item 2 and Ref.12). It was subsequently determined that tolerance stackups within the original ~.005" TIR are acceptable and would not contribute to a failure-to-start condition.
The root cause of the failure to start condition was determined to be associated with excessive startup shaft deflections and resonant characteristics peculiar to the particular frame 5010 500 hp motors as discussed in III.B.
During testing of LPSI IB (with its 500 hp motor and with above Items 1-4 implemented) another failure to start occurred on-January 29, 1984 (the unit was tripped manually after two seconds). As with previous failed starts, the shaft rotated
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Mr. D. F. Kirsch p ANPP-31676 Page Five ,
i slowly-prior to the trip and was free to rotate by hand thereafter. Unlike previous failed starts, the unit was ,
successfully restarted six times on January 30, 1984. .
l Subsequent disassembly and inspection disclosed light contact L at the lower clearance, and the lower case ring was angularly l ,
displaced approrisately 1/4".
III.B. Corrective Action, LPSI Pump Motors ,
i As documented and presented in detail in the C-E report j' (Ref.'9), it was concluded that due to the shaft flexibility i in combination with transient electromagnetic starting forces, this particular 500 hp motor (frase 5010) is unsuited for reliable use with the WDF type pump, in spite of the i sitigating effects of Corrective Action Items 1-4 above.-
I Contact between impellers and case rings during startup does not in itself cause failure to start, but has been demonstrated to be a precondition of the failure-to-start '
, mechanism.
t Measurements of startup shaft end and impeller lower running i_ surface deflections in air (without case rings, stuffing box i bushing or shaft seals to restrain radial movement) have shown
> that ispeller-to-case ring contact would consistently occur with the original 500 hp LPSI pump' motors if started dry in an
, assembled pump, and would.probably also occur when started in a pump full of water. Comparable seasurements have shown that l the 800 hp CS pump motor, with its . stiffer shaft between l bearings,'1arger frame size and.different electromagnetic, starting forces does not exhibit startup deflections with either LPSI or CS. impellers which would cause contact either
' dry in an assembled pump or in a pump full of water, (Ref. 4 '
i and 6). Therefore, to minimize startup deflections, an 800 hp
! CS pump motor was installed on the LPSI pump.
It was--determined that a 100 start test with no failures would i demonstrate adequate reliability with 95% confidence for a.
l pump / motor set (Ref. 5). The following items were therefore implemented.
- 1. An 800 hp CS pump motor from Unit 3 was installed on the '
LPSI 1B pump (Ref. 6).
~ The pump / motor set 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 '
f hearing temperatures. .It was then restarted 5 times (20 ;
4 ' minutes run time for the first four starts to satisfy motor l 4 . cooling requirements). Subsequent disassembly and .l inspection on March 3, 1984, revealed light contact at the 1
'Jover impeller clearance (360*)'with corresponding contact at approximately 270* of the lower case ring on the side away from the pump. discharge connection.
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Mr. D. F.~-Kirsch ANPP-31676 Page Six
- 2. The pump was reassembled and 100 additional starts were made. All runs were approximately 20 minutes duration and at 2000 to 2100 spe valve setting. The first run (after refilling and venting) started at approximately 100 spo through the minimum flow line, the same as in Paragraph I above. 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 Ites 1 above. The contact surfaces of- the Nitronic 60 case rings were smooth with a light intermittent film transfer to the four impeller running surface lands.
At a March 9, 1984 meeting, APS, Bechtel, C-E, and IR agreed.that the light rubs were normal and within acceptable limits (Ref. 7). The significance of no evidence of contact on 900 of the lower case ring indicates startup deflections are not resulting in contact. The 270' contact resulted from the brief operation at minimum flow where pumps characteristically rua rougher than at higher flows. It was further agreed that the test showed this particular 800 hp motor (frame 5809 with a 6" disseter shaft between bearings) would operate reliably in combination with the WDF type pump (either 8 x 20 or 8 x 23 sizes).
- 3. All six LPSI pump motors from Units 1, 2, and 3 were 8 replaced by six new Westinghouse frame 5809 800 hp motors.
These new motors will be duplicates of and interchangeable with the original CS pump motors (Ref. 4). This motor replacement was accomplished in accordance w1th DCP .1SM, .l 2SM, and 3CM-SI-117.
The increased startup inrush current (800 vs 500 hp) is .
within the capacity of the diesel. generators. The LPSI
-breaker settings were changed to accommodate the GOO hp motor. In addition, the original current transformer (100/5 esp.) was replaced (150/5 asp.) and the'asseter was changed from a 0-100 to 0-150 scale meter.
- 4. SAR Change Notice 1180 has been initiated to revise affected sections of the FSAR for the change in LPSI pump-motors.
- 5. Since completion of the 100 start test and as of August 8, I 1984, Unit 1 LPSI pumps A and B havs been started 36 times and 46 times, respectively, without any. difficulties.
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' Mr. D. F. Kirsch ANPP-31676
.Page Seven
! Disassembly and inspection'of these pumps during the time peried of additional starts have not disclosed any abnormal ,
wear patterns.
Also, CS pump A has been started 48 times and CS pump B, 46 times. Inspection after additional operation revealed no abnormal wear patterns. These particular pump /sotor sets have .never had a failure-to-start problem.
i Since August 8, 1984, to date, the Unit 1 LPCI and CS pumps i as well as the Unit 2 LPSI and CS pumps have been started 1 '- numerous times with various valve alignments without any startup difficulties, i
III.C. Corrective Action, Miscellaneous
- 1. Regarding NCRs SM-2756 and 2757, additional field
- i. performance tests after final sodifications of both Unit 1 LPSI pumps have verified that the head-capacity
! characteristics from minieue flow to; runout are acceptable, i.e., above ECCS minimus, (Ref. 8). These tests were i conducted to verify that the head loss due to increasing tba impeller-to-case ring clearances was within acceptable
! limits. These particular NCRs were assigned to this DER only because they related to LPSI pumps, and were not in any way related to the failure-to-start issue.
l 2. NCR SM-3418 was dispositioned to have the impeller returned to IR for rework to correct the bore dimension.
- 3. NCR SM-3588 was dispositioned to cleanup the impeller and replace the lower case ring after rubs had occurred while l, operating with a 500 hp motor on January 18, 1984. ,
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if Mr. D. = F. Kirsch ANPP-31676
'Page Eight IV. References (1) V-CE-19299, dated Nov.-11,.1983 (2) V-CE-19218, dated Oct. 28,'1983 (3) -V-CE-19298, dated Nov.- 11, 1983 (4) V-CE-30175, dated Apr. 30, 1984 0
(5) V-CE-20584, dated Jan. 26,.1984 (6)V-CE-19784, dated Feb. 20, 1984 (7) V-CE-21628, dated Mar. 9, 1984 (8) V-CE-21710, dated June 11, 1984 (9) V-CE-30704, dated Aug. 2, 1984, Combustion Engineering Report CEN-285(V)-P, "Palo Verde Nuclear Generating Station Low Pressure Safety Injection Pumps Failure to Start" (10) V-CE-19348, dated Nov. 23, 1983 (11) V-CE-19389, dated Dec. 1, 1983 (12) V-CE-20536, dated Dec. 2, 1983 4
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