ML17264A606

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LER 96-009-01:on 960723,leakage Outside Containment Occurred,Due to Weld Defect,Resulting in Leak Rate Greater than Program Limits.Source of Leakage Isolated from RWST by Freeze Seal,Allowing Exit from ITS LCO 3.0.3.W/960919 Ltr
ML17264A606
Person / Time
Site: Ginna Constellation icon.png
Issue date: 09/19/1996
From: MECREDY R C, ST MARTIN J T
ROCHESTER GAS & ELECTRIC CORP.
To: VISSING G S
NRC (Affiliation Not Assigned), NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
LER-96-009, LER-96-9, NUDOCS 9609270259
Download: ML17264A606 (13)


Text

4CATEGORYjREGULATEYINFORMATIONDISTRIBUTIOdYSTEM(RIDS)ACCESSIONNBR:9609270259DOC.DATE:96/09/19NOTARIZED:NODOCKETACIL:50-244RobertEmmetGinnaNuclearPlant,Unit1,RochesterG05000244'UTH.NAMEAUTHORAFFILIATIONSTMARTIN,J.T.RochesterGasaElectricCorp.MECREDY,R.C.RochesterGas&ElectricCorp.RECIP.NAMERECIPIENTAFFILIATIONVISSINGiG.S.

SUBJECT:

LER96-009-01:on960723,leakageoutsidecontainmentoccurred,duetowelddefect,resultingleakrategreaterthanprogramlimit.SourceofleakagewasisolatedfromRWSTbyfreezeseal,allowingexitfromITSLCO3.0.3.W/960919ltr.DISTRIBUTIONCODE:IE22TCOPIESRECEIVED:LTRUENCL/SIZE:TITLE:50.73/50.9LicenseeEventReport(LER),IncidentRpt,etc.NOTES:LicenseExpdateinaccordancewith10CFR2,2.109(9/19/72).05000244INTERNAL:RECIPIENTIDCODE/NAMEPD1-1PDILECENTERNRDEELBNRR/DRCH/HHFBNRR/DRCH/HOLBNRR/DRPM/PECBNRR/DSSA/SRXBRGN1FILE01COPIESLTTRENCL111111111111111111RECIPIENTIDCODE/NAMEVISSINGiG.AEOD/SPD/RRABNRR/DE/ECGBNRR/DE/EMEBNRR/DRCH/HICBNRR/DRCH/HQMBNRR/DSSA/SPLBRES/DSIR/EIBCOPIESLTTRENCL1111111111111111DEXTERNAL:LSTLOBBYWARDNOACMURPHYiG.ANRCPDR111111LITCOBRYCEgJHNOACPOORE,W.NUDOCSFULLTXT111111NNOTETOALL"RIDS"RECZPIENTS:PLEASEHELPUSTOREDUCEWASTE'ONTACTTHEDOCUMENTCONTROLDESK,ROOMOWFN5D-5(EXT.415-2083)TOELIMZNATEYOURNAMEFROMDISTRIBUTIONLISTSFORDOCUMENTSYOUDON'TNEED!FULLTEXTCONVERSIONREQUIREDTOTALNUMBEROFCOPIESREQUIRED:LTTR23ENCL23 I)

~d~dANDROCHESTERGASANDELECTRICCORPORATION~B9EASTAVENIJE,ROCHESTER,N.YId6d9.060IAREACODE7165'-2700ROBERTC.MECREDYVicePtetdttentNvcfeorOperotdoosSeptember19,1996U.S.NuclearRegulatoryCommissionDocumentControlDeskAttn:GuyS.VissingProjectDirectorateI-1Washington,D.C.20555'd

Subject:

LER96-009,LeakOutsideContainment,DuetoWeldDefect,ResultsinLeakRateGreaterThanProgramLimitR.E.GinnaNuclearPowerPlantDocketNo.50-244Inaccordancewith10CFR50.73,LicenseeEventReportSystem,item(a)(2)(i)(B),"Anyoperationorconditionprohibitedbytheplant'sTechnicalSpecifications",theattached'sujyleiiieilt::,';toLicenseeEventReportLER96-009isherebysubmitted.EntryintoLimitingNkv~ConditionforOperation3.0.3ofTechnicalSpecificationswas6ise4:;:,.upo@:,Gie'i'a>84'0'ko7iXCCC~a':.:.eCCRU.OvN$5':S".'2'-:."Pd'dId0ddC'd((vs(wv((Ox'vt4mv4vdv((((vdv(((dvvvv(wdvd~~Mdvvvvv((w(..(vcvr((~..v((d~"vvv'.:'d(wNv'vMv'dv((xc'i'i'v'c.,xv~viNv(((((ddvw~cvMvwVAYwvÃ4xvdeThiseventhasinnowayaffectedthepublic'shealthandsafety.Vetrulyyours,RobertC.Mecreyxc:Mr.GuyS;Vissing(MailStop14C7)PWRProjectDirectorateI-1Washington,D.C.20555U.S.NuclearRegulatoryCommissionRegionI475AllendaleRoadKingofPrussia,PA19406GinnaSeniorResidentInspector9609270259960919PDRADOCK05000244SPDR 4

NRCFORM366(4.95)U.S.NUCLEARREGULATORYCOMMISSIOLICENSEEEVENTREPORT(LER)(Seereverseforrequirednumberofdigits/charactersforeachblock)APPROVEDBYOMBNO.3150%104'XPIRES04/30/98ESTIMATEDBURDENPERRESPONSEToCOMPLYWITHTHISMANDATORYINFORMATIONCOLLECTIONREQUEST:50.0HRS.REPORTEDLESSONSLEARNEDAREINCORPORATEDINTOTHELICENSINGPROCESSANDFEDBACKToINDUSTRYFORWARDCOMMENTSREGARDINGBURDENESTIMATEToTHEINFORMATIONANDRECORDSMANAGEMENTBRANCHIT-BF33),U.S.NUCLEARREGULATORYCOMMISSION,WASHINGTON.Dc20555-0001ANDToTHEPAPERWORKREDUCTIONPROJECTFAGIUTYRAMEIllR.E.GinnaNuclearPowerPlantoocKETrrUMSDII2I05000244PAOEIsl1OFRTITLEI4)LeakOutsideContainment,DuetoWeldDefect,ResultsinLeakRateGreaterThanProgramLimitEVENTDATE(5)LERNUMBER(6)REPORTDATE(7)OTHERFACILITIESINVOLVED(8)MONTHDAYYEARSEQUENTIALREVISIONNUMBERNUMBERDAYYEARFACIUTYIrAMEOOCKETkUMSER072396,96-009-01091996FACILityNAMEDOCKETNVMBEROPERATINGMODE(9)POWERLEVEL(10)10020.2201(b)20.2203(a)(1)20.2203(a)(2)(i)20.2203(a)(2)(ii)20.2203(a)(2)(iii)20.2203(a)(2)(v)20.2203(a)(3)(i)20.2203(a)(3)(n)20.2203(a)(4)50.36(c)(1)X50.73(a)(2)(i)50.73(a)(2)(ii)50.73(a)(2)(iii)50.73(a)(2)(iv)50.73(a)(2)(v)50.73(a)(2)(viii)50.73(a)(2)(x)73.71OTHERSpecifyinAbstractbeloworInNRCForm3BBATHISREPORTISSUBMITTEDPURSUANTTOTHEREQUIREMENTSOF10CFRE:(Checkoneormoro)(11)20.2203(a)(2)(iv)50.36(c)(2)LICENSEECONTACTFORTHISLER(12)50.73(a)(2)(vii)NAMETELEPHONENUMBER(IooiudaAreaCoda)JohnT.St.Martin-TechnicalAssistantCOMPLETEONELINEFOREACHCOMPONENTFAILUREDES(716)771-3641CRIBEDINTHISREPORT(13)CAUSESYSTEMCOMPONENTMANUFACTURERREPORTABLETONPRDSCAUSESYSTEMCOMPONENTMANUFACTURERREPORTABLEToNPRDS'BEPSFSUPPLEMENTALREPORTEXPECTED(14)YES(Ifyes,completeEXPECTEDSUBMISSIONDATE).XNOEXPECTEDSUBMISSIONDATE(15)MONTHDAYYEARABSTRACT(Limitto1400spaces,i.e.,approximately15single-spacedtypewrittenlines)(16)OnJuly23,1996,atapproximately0857EDST,itwasdeterminedthattheleakrate(fromaleakonapipingsystemoutsideContainment)wasgreaterthantheanalyzedvalueoftwogallonsperhourforaprimarycoolantsourceoutsideContainment.ImmediatecorrectiveactionwastoconservativelyenterTechnicalSpecificationLimitingConditionforOperation3.0.3andinitiateaplantshutdown,andtoinitiateactionstoisolatetheleakusingafreezeseal~Oncetheleakwasisolated,theplantexitedTechnicalSpecification3.0.3andtheshutdownwasstopped.Theleakingpipewascutoutandreplaced.Theunderlyingcauseoftheleakwasawelddefectwhichdatesbacktooriginalconstructioninthe1960's.ThiseventisNUREG-1022CauseCode(B).CorrectiveactiontopreventrecurrenceisoutlinedinSectionV.B.Additionalcorrectiveactionsw((I-beEIr6identifiedinthissupplement.te-t)t(e-GERNRCFORM3BB(4-B5)

NRCFORM366AI4-95)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSION,r'ACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET05000244LERNUMBER(6)YEARSEQUENTIALREVISIONNUMBERNUMBER96-009-01PAGEI3)2OFNTEXTllfmorespaceisrequired,useadditionalcopiesofNRCForm366AI(17)I.PRE-EVENTPLANTCONDITIONS:OnJuly22,1996,theplantwasinMode1atapproximately100%steadystatereactorpower.Atapproximately1130EDST,aRadiationProtection(RP)technician,whowasperformingaroutineweeklysurveyoftheAuxiliaryBuilding,observedwaterdrippinginanareabehindtheRefuelingWaterStorageTank(RWST).TheRPtechniciannotifiedtheControlRoomoperators.EffortstolocatethesourceofthedrippingwaterandtoquantifytheteakratewereinitiatedbyOperationsandNuclearEngineeringServices(NES).ThesourceofwaterwasdeterminedtobeasmallleakonatestlinefortheContainmentSpray(CS)systemintheAuxiliaryBuilding,whichisoutsidetheContainment(CNMT).Theleakratewasestimatedtobeapproximatelyone(1)gallonperhour(GPH).TheControlRoomoperatorsdidnotidentifyanyrequirementthatwouldlimitplantoperations.TheShiftSupervisornotifiedOperationsmanagement,maintenancemanagement,andplantandNESstaffoftheleak.Allreachedasimilarconclusion.Thestaffworkedondevelopingandimplementinganactionplantoaddresstheproblem.TheissuesoflineintegrityandRWSToperabilitywereinvestigatedbyNESandLaboratoryInspectionServices(LIS)personnel.LISpersonnelmeasuredtheamountofpipecross-sectionandweldmetalremaining,andNESpersonneldeterminedthattherewasamplemetalintheaffectedareatoprovidesystemintegrity.Thesourceoftheleakwasidentifiedasasmallpinholeleakonapipe-to-90degreeforgedsocketelbowweldonatwo(2)inchnominalpipesizeSchedule10stainlesssteeltestlinefortheCSsystem.TheleakwasinapartoftheCSsystemthatcouldnotbeisolatedfromtheRWSTbyvalvemanipulationswithoutmakingbothtrainsoftheemergencycorecoolingsystem(ECCS)inoperable.Theleakwasmonitoredthroughouttheremainderofthedayandnight.AnoperabilityassessmenthadbeenrequestedbytheShiftSupervisoronJuly22V'iheo':th'e,'edst'soGe:-ofgthajja'aTth36rlstbIaaidtirdttfjid.QnthemorningofJuly23,1996,thisassessmentwasreviewedbythePlantOperationsReviewCommitteeiPORCi.Thisassessment,whichwasbasedonconservativeassumptions,concludedthattheRWSTandECCSwerestilloperablewiththeunisolatedleak.Thisconclusionwassupportedbythefactthattherewasstillamplemetalareainthecross-sectionthatcouldprovideintegrityofthepipeduringaseismiceventandthatthetotalcombinedstresswaslessthantheyieldstrengthofthematerial.PORCrequestedamoreaccurateestimateoftheleakrate.TheleakratewasmeasuredandestimatedtobeQ-.S2.:8GPH.Thisleakrateisinexcessoftwo(2)GPH,whichisspecifiedinSurveillanceTestProcedurePT-39,"LeakageEvaluationofPrimaryCoolantSourcesOutsideContainment",astheprogramlimitforthemaximumintegratedleakrateoutsideCNMTfromthesesources.TheleakrateexceededtherequirementsofprocedurePT-39,anditwasinitiallyjudgedtobeaviolationofthe"PrimaryCoolantSourcesOutsideContainmentProgram",asspecifiedintheGinnaStationImprovedTechnicalSpecifications(ITS)Section5.5.2.Operation(LCO)3.0.3,basedontheCOI1Ser'Vat)vdrequirementsofprocedurePT-39andAdministrativeProcedureA-52A,"ControlofLimitingConditionsforOperatingEquipment",eventhoughtheplantwasincompliancewithallITSLCOs.NRCFORM366AI4-95)

NRCFORM366A(4-95)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET05000244LERNUMBER(6)YEARSEQUENTIALREVISIONNUMBERNUMBER96-009-01PAGE(3)3OFITEXTIifmorespeceisrequired,useedditionelcopiesofNRCForm366AI(17);II.DESCRIPTIONOFEVENT:A.DATESANDAPPROXIMATETIMESOFMAJOROCCURRENCES'July22,1996,1130EDST:AleakisidentifiedonalineoutsideofContainment.oJuly23,1996,0857EDST:EventDateandTimeandDiscoveryDateandTime.oJuly23,1996,0900EDST:Loadreductionisstarted.oJuly23,1996,1440EDST:IntegratedleakageoutsideContainmentisdeterminedtobelessthantwoGPH.Loadreductionisstopped.BvEVENT'nJuly23,1996,atapproximately0857EDST,withtheplantinMode1atapproximately100%steadystatereactorpower,thePlantOperationsReviewCommittee(PORC)conservativelydirectedtheShiftSupervisortoenterITSLCO3.0.3.TheShiftSupervisordirectedtheControlRoomoperatorstoinitiateaplantshutdown.Atapproximately0900EDST,theControlRoomoperatorsinitiatedaplantshutdownperNormalOperatingProcedure0-2.1,"NormalShutdowntoHotShutdown".TheMechanicalSupportgroupinitiatedactionstoprovideafreezesealtoisolatethesourceofleakagefromtheRWST.AfreezesealwasinitiatedbetweentheleakingsocketandtheCSpumpsuctionlinefromtheRWST.Atapproximately1440EDSTonJuly23,1996,thefreezesealhadisolatedtheleak.ITSLCO3.0.3wasexitedandtheloadreductionwasstopped.Theaffectedpipeandsocketweldswerecutoutandanewprefabricatedspoolpiecewasinstalled.Theaffectedweldwasretainedforfailuremodeanalysis.Aloadincreasetoreturntheplanttofullpowerwasinitiatedatapproximately1530EDSTonJuly23,1996.C.INOPERABLESTRUCTURES,COMPONENTS,ORSYSTEMSTHATCONTRIBUTEDTOTHEEVENT:NoneD.OTHERSYSTEMSORSECONDARYFUNCTIONSAFFECTED:Duetothelocationandsizeoftheleak,anoperabilityassessmentdeterminedthatnoemergencysafeguardssystemfunctionwasmadeinoperable.However,theleakwasnotisolablefromtheRWSTwithoutvalvemanipulationsthatwouldhaveresultedintheinoperabilityoftheRWSTandbothtrainsoftheECCS.NRCFORM366A(4-95)

NRCFORM366A~(4-96)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET05000244LERNUMBER(6)YEARSEQUENTIALREVISIONNUMBERNUMBER96-009-01PAGE(3)ZTEXTllfmorespaceisrequired,useeddidonelcopiesofNRCForm366A/(17)METHODOFDISCOVERY:TheleakwasfirstdiscoveredbyanRPtechnicianduringaroutineweeklysurveyoftheAuxiliaryBuilding.HenotifiedtheControlRoomoperators,andthepreciselocationwasconfirmedbyOperationsandEngineering.Confirmationthattheleakratewasabove2GPHoccurredaftermeasurementsperformedatthedirectionofPORC.OPERATORACTION:WhennotifiedbyPORC,theShiftSupervisordirectedtheControlRoomoperatorstoenterITSLCO3.0.3andtoinitiateaplantshutdown.TheControlRoomoperatorsinitiatedaplantshutdownperprocedure0-2.1.TheShiftSupervisorsubsequentlynotifiedtheNRCper10CFR50.72(b)(1)(i)(A),non-emergencyonehournotification,atapproximately0951EDSTonJuly23,1996.Whentheteakwasisolated,ITSLCO3.0.3wasexited,andtheplantwasreturnedtofullpower.G.SAFETYSYSTEMRESPONSES:NoneIII.CAUSEOFEVENT:A.IMMEDIATECAUSE:TheimmediatecauseoftheconditionprohibitedbyTechnicalSpecificationswastheconservativedeterminationbyPORCtoenterITSLCO3.0.3duetotheleak.B.INTERMEDIATECAUSE:Theintermediatecauseoftheleakwasapinholeleakintheweldattachingthepipetothesocketelbow.C.ROOTCAUSE:Theaffectedpipe,socket,andfilletweldwereanalyzedforthefailuremode.Thepinholewasdeterminedtobeanoriginalinstallationwelddefect(datingfromthe1960's)thatexistedoveranareaofslaginclusionintheweld.Almostalltheslaghadbeenleachedfromthepinholechanneloverthepast25years.ThiseventisNUREG-1022CauseCode(B),"Design,Manufacturing,Construction/Installation".NACFOAM366A(4-95) rrNRCFORM366A~(4-95)LICENSEEEVENTREPORT.(LER)TEXTCONT(NUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET05000244LERNUMBER(6)YEARSEQUENTIALREVISIONNUMBERNUMBER96-009-01PAGE(3)5oFITEXTllfmorespaceisrequired,useadditionalcopiesofNRCForm366AJ(17)Lnn'etteiiiart::::FiiitriIiirev)IV.ANALYSISOFEVENT:Thiseventisreportableinaccordancewith10CFR50.73,LicenseeEventReportSystem,item(a)(2)(i)(B),"Anyoperationorconditionprohibitedbytheplant'sTechnicalSpecifications".Theintegratedleakrateinexcessof2GPHoutsideCNMTresultedinconservativeentryintoITSLCO3.0.3.nieces':.'ttvI'ee"ltaharsiinit't1aIis',::she)areas':iThh,:::,LCCr';nrVrrrWhhaehehWPWrVhrnVhnrWhhrWhVaaPhsnhereneVnWWhW4VeVhWehWVhVhVh~ehVhVnahhVhVhhrVeSNWhWhWWrhehrhVhWWieaWWWh4(tniaaaiiPnyeyt:wsa::trver:,,ierrnredheanatdstarred.:rtrairntteVlJ@'Itr'Sitlfeireenttaiiartdietrrr'rasarehatntittrtaeaael'Iaarvneht'ntiiresvse'rs'neetreraticirialrrLeiifs+ionssquineaeanrtmji!ieeneneanr!GFtsdantt7i!eakrtntheCS.t~~lILLe,::::baacva'USB:,"-rtrr'eintra'n'a'd'b'y'!th'aiiiiatr'nvn'roti't":."tit)ascii'ifailetie'ntetcttI!dStrhae'dtesaiialtItr'IIL(at(j':::(dandified;OSp'Ber'it(Or'i'::Ofhl'th'6CB;O'r:;:Bastfert~y!ira)leoatiOSji;MANICeawhe~vvsvhawhwwIsnhshvhvwh I

~~NRCFORM366A(4-95)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET05000244LERNUMBER(6)YEARSEQUENTIALREVISIONNUMBERNUMBER96-009-01PAGE(3)80.FITEXTllfmorespaceisrequired,useadditionalcopiesofNRCForm386Al(17)PyPheeeyfdeePheeehoPeeehw%...,%..;,:':,'"'"vvvvewheheehwvhONew.hvh~whivvwhevhvO.evhAN&hVhOShe(vevhwhvevhV'vN~Seeheehw'vVh~...v4@.ewVevhwhvhi8DC1'"'i':9.tt'sssdioiiitbeebovei"::.,:fi:::oso!bs::,.":ooootedsdibet'."tbspoblto~s:b7iiljb.::sIodv::,:ssrsty-:::.vsse:sssoted."(st"::sitrtt~egV.CORRECTIVEACTION:A.ACTIONTAKENTORETURNAFFECTEDSYSTEMSTOPRE-EVENTNORMALSTATUS:ThesourceoftheleakagewasisolatedfromtheRWSTbyfreezeseal,permittingexitfromITSLCO3.0.3.0Theaffectedpipeandsocketweldswerecutoutandreplacedwithanewprefabricatedspoolpiece,andthefreezesealwasremoved.ACTIONTAKENORPLANNEDTOPREVENTRECURRENCE:1oFailureAnalysisoftheleakinthesocketweldhasbeenperformed.o~Theadjacentoriginalexistingweldswerecutoutandreplaced.oAdditionalcorrectiveactionsvd(I(-beareidentifiedinthissupplement'te-th(e-GERBr(ed:::arevIlisted:;ef~w:v~hwwevwwh'svwstiinir'o'iily;"oii",vsiiifi'ref::;b'os'i::isiiioviil::byii'tiiboiviL(ttH~vtRtL:;v".'"ipisj'j'"iiri'd::w'ii(itai:::;:,St::eoed:,CS!ptpiovt;O:NYN%""""AI4wS,N"vOhvs.hv';"::;Cooistiiiri'Ct1(df!oiis'shiit'xiii(v'::"ooii's'idee'Ih'sfiioioiVsyehevhwwhvh(hvwhvvwv'1vwhvhevwwwhvsvhvwvhvNRCFORM366A(4-95)

NRCFORM366A(4-95)L1CEHSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET05000244LERNUMBER(6)YEARSEQUENTIALREVISIONNUMBERNUMBER96-009-01PAGE(3)NOFNTEXTIifmorespeceisrequired,useedditionalcopiesofNRCForm366AI(17)Vl.ADDITIONALINFORMATION:A.FAILEDCOMPONENTS:Thefailedcomponentwasa2inchnominalpipesizeSchedule10pipe-to-90degreeforgedsocketelbowweld.Thepipeandsocketelbowarestainlesssteel,ASTMA312Type304andA182F304(forged)respectively.Thesocketweldwasanoriginalinstallationweldmadebefore1970.B.PREVIOUSLERsONSIMILAREVENTS:AsimilarLEReventhistoricalsearchwasconductedwiththefollowingresults:NodocumentationofsimilarLEReventswiththesamerootcauseatGinnaNuclearPowerPlantcouldbeidentified.C.SPECIALCOMMENTS:NoneNACFORM366A(4.96)