ML17263A983

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LER 95-001-00:on 950203,pressurizer Safety Valves Lift Settings Found Above TS Tolerance During post-svc Test,Due to Setpoint Shifts That Resulted in Independent Trains Being Considered Inoperable
ML17263A983
Person / Time
Site: Ginna Constellation icon.png
Issue date: 03/06/1995
From: ST MARTIN J T
ROCHESTER GAS & ELECTRIC CORP.
To:
Shared Package
ML17263A982 List:
References
LER-95-001, LER-95-1, NUDOCS 9503160241
Download: ML17263A983 (9)


Text

NRCFORH366(5-92).S.NUCLEARREGULATORY COHHISSION PPROVEDBYOHBNO.3150-0104 EXPIRES5/31/95LICENSEEEVENTREPORT(LER)(Seereverseforrequirednumberofdigits/characters foreachblock)ESTIMATED BURDENPERRESPONSETOCOHPLYWITHTHISINFORMATION COLLECTION REQUEST:50.0HRS.FORWARDCOHMENTSREGARDING BURDENESTIMATETOTHEINFORMATION ANDRECORDSMANAGEMENT BRANCH(HNBB7714),U.STNUCLEARREGULATORY COHHISSION, WASHINGTON, DC20555-0001, ANDTOTHEPAPERWORK REDUCTION PROJECT(3150-0104),

OFFICEOFHANAGEHENT ANDBUDGETWASHINGTON DC20503.FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKETNUMBER(2)05000244PAGE(3)10F9TITLE(4)Pressurizer SafetyValvesLiftSettingsFoundAboveTechnical Specifications Tolerance DuringPost-service Test,DuetoSetpointShifts,ResultsinIndependent TrainsBeingConsidered Inoperable HONTH02DAYYEAR0395EVENTDATE(5)YEAR95LERNUHBER(6)SEQUENTIAL NUHBER--001--REVISIONNUHBER00MONTHDAY0306YEARREPORTDATE(7)FACILITYNAHEDOCKETNUMBERFACILITYNAMEDOCKETNUMBEROTHERFACILITIES INVOLVED(8)OPERATING HODE(9)POWERLEVEL(10)N098THISREPORTISSUBMITTED PURSUANT20.402(b) 20.405(a)(1)(i)20.405(a)(1)(ii) 20.405(a)(1)(iii) 20.405(a)(1)(iv) 20.405(a)(1)(v) 20.405(c) 50.36(c)(1) 50'6(c)(2)50.73(a)(2)(i) 50.73(a)(2)(ii) 50.73(a)(2)(iii) 50.73(a)(2)(iv) 50.73(a)(2)(v)

X50.73(a)(2)(vii) 50.73(a)(2)(viii)(A) 50.73(a)(2)(viii)(B) 50.73(a)(2)(x) 73.71(b)73.71(c)OTHER(SpecifyinAbstractbelowandinText,NRCForm366A)TOTHEREQUIREMENTS OF10CFR5:(Checkoneormore)(11)LICENSEECONTACTFORTHISLER(12)NAMEJohnT.St.Hartin-Technical Assistant TELEPHONE NUMBER(IncludeAreaCode)(315)524-4446COHPLETEONELINEFOREACHCOHPONENT FAILUREDESCRIBED INTHISREPORT(13)CAUSESYSTEHCOMPONENT RVHANUFACTURER C170REPORTABLE TONPRDSCAUSESYSTEHCOMPONENT MANUFACTURER REPORTABLE TONPRDSSUPPLEHENTAL REPORTEXPECTED(14)YES(Ifyes,completeEXPECTEDSUBHISSION DATE).XNOEXPECTEDSUBHISSIONDATE(15)MONTHDAYYEARABSTRACT(Limitto1400spaces,i.e.,approximately 15single-spaced typewritten lines)(16)OnFebruary3,1995,atapproximately 1824EST,withthereactoratapproximately 98'.steadystatepower,bothpressurizer safetyvalves,whichhadbeenpreviously installed andthenremovedfortesting,wereconsidered inoperable.

Recenttestresultsdiscovered thatthe"as-found" setpressurefortheliftsettingshadshiftedabovethetolerance intheTechnical Specifications.

Immediate corrective

.actionwasnotrequired, sincethevalveswerenotinstalled.

Theunderlying causeofthesetpointshifthasbeenattributed toacombination offactors,including long-term operation, removalandshippingtoanoff-sitefacilityfortesting,aswellasarestrictive tolerance intheTechnical Specifications.

ThiseventisNUREG-1022 CauseCode(B).Corrective actiontoprecluderepetition isoutlinedinSectionV.B.9503160241 950306PDRADOCK050002448PDRNRCFORH366(5-92)

NRCFORM366A(5-92).S.NUCLEARREGULATORY COMHISSION LICENSEEEVENTREPORT(LER)TEXTCONTINUATION PPROVEDBYOHBNO.3150.0104 EXPIRES5/31/95ESTIMATED BURDENPERRESPONSETOCOMPLYWITHTHISINFORMATION COLLECTION REQUEST:50.0HRS.FORWARDCOHMENTSREGARDING BURDENESTIHATETOTHEINFORHATION AHDRECORDSMANAGEMENT BRANCH(MNBB7714),U.S.NUCLEARREGULATORY COMMISSION, WASHINGTON, DC20555-0001, ANDTOTHEPAPERWORK REDUCTION PROJECT(3150-0104),

OFFICEOFHANAGEHEHT ANDBUDGETWASHINGTON DC20503.FACILITYNAHE(1)R.E.GinnaNuclearPowerPlantDOCKETNUHBER(2)05000244YEAR95LERNUHBER(6)SEQUENTIAL 001REVISIONUM00PAGE(3)2OF9TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366A)(17)I.PRE-EVENT PLANTCONDITIONS:

Theplantwasatapproximately 98'.steadystatereactorpowerwithnomajoractivities inprogress.

Twonewpressurizer (PRZR)codesafetyvalveshadbeenpurchased, andweretestedinthespringof1993atthevalvemanufacturer's testfacilities.

ThevalveswereshippedtoRochester GasandElectric(RGEE)withan"as-left" setpressureof2485psig(+/-1'.TheoriginalsafetyvalvesatGinnaStationwereremovedduringthe1993outageforannualtesting,andthesetwonewsafetyvalveswereinstalled.

Thesevalves(V-434andV-435)werethenconsidered operableduringthe1993/1994 operating cycle(cycle23)~Thesetwovalveswerethenremovedforannuallifttestingduringthe1994outage,andtheoriginalpairofsafetyvalves(whichhadbeentestedin1994)wereinstalled forthe1994/1995 operating cycle(cycle24).TheremovedvalveswereshippedtoatestfacilityinHuntsville, Alabama,fortesting,asperRGEEpurchaseorderNQ-14349-C-JW.

Thevalvesweretestedtotherequirements ofRGGETestSpecification MET-049,"Pressurizer SafetyReliefValveSetpointTesting",

withsteamasthetestmedium,onJanuary10,1995(forV-434)andJanuary11,1995(forV-435).RGEEQualityAssurance (QA)witnessed thetests.Thetestresultsshowedthatthe"as-found" setpoints were2525psig(forV-434)and2543psig(forV-435),whichexceededthe1.liftsettingtolerance ofTechnical Specifications.

Theseresultswererecognized asnonconforming, andaNonconformance Report(NCR95-005)wasinitiated todocumentthiscondition.

OnFebruary3,1995,duringreviewofNCR95-005bySystemEngineering andNuclearEngineering Services(NES),itwasdetermined thatthisrepresented apotentially reportable condition.

NRCFORM366A(5-92)

NRCFORM366A(5-92).S.NUCLEARREGULATORY COMMISSION LICENSEEEVENTREPORT'(LER)

TEXTCONTINUATION PPROVEDBYOHBNO.3150~0104EXPIRES5/31/95ESTIMATED BURDENPERRESPOHSETO.COMPLYWITHTHISIHFORHATION COLLECTIOH REQUEST:50.0HRS.FORWARDCOHHENTSREGARDIHG BURDENESTIHATETOTHEINFORMATION ANDRECORDSMANAGEMENT BRANCH(MHBB7714),UPS.NUCLEARREGULATORY COHHISSION,

'WASHINGTON, DC20555-0001 AHD-TOTHEPAPERWORK REDUCTION PROJECT(31i0-0104),

OFFICEOFHAHAGEMENT AHDBUDGETWASHINGTON DC20503.FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKETNUHBER(2)05000244YEAR9500100LERNUHBER(6)SEQUENTIAL REVISIONPAGE(3)3OF9TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366A)(17)A.DESCRIPTION OFEVENT:DATESANDAPPROXIMATE TIMESOFMAJOROCCURRENCES:

1.March,1993:NewlyprocuredPRZRsafetyvalvesaresatisfactorily testedatmanufacturer's testfacility.

2.April,1993:NewlyprocuredPRZRsafetyvalvesareinstalled forthe1993/1994 operating cycle(cycle23).3.January11,1995:Testingofsafetyvalvescompleted atoff-sitetestingfacility.

Testresultsshowthattheliftpressureexceededtheliftsettingtolerance.

Eventdateandtime.4.February3,1995,1824EST:TestresultsarereviewedwiththeSystemEngineer.

Discovery dateandtime.5.February3,1995,2011EST:ShiftSupervisor notifiesNRCper10CFR50.72.B.EVENT:OnFebruary3,1995,atapproximately 1824EST,thereactorwasatapproximately 98'.steadystatereactorpower,andnomajoractivities wereinprogress.

NESpersonnel, fromMechanical Engineering andNuclearSafetyandLicensing (NSEL),werereviewing thestatusofNCR95-005withtheSystemEngineer.

ReviewoftheNCRsuggested

'anoperability questioninvolving thesepreviously, installed safetyvalves.Sincebothvalveswerepreviously installed duringcycle'23,itwasconservatively assumedthatthevalveshadshiftedoutoftolerance duringcycle23.HRCFORH366A(5-92)

NRCFORH366A(5-92).S.NUCLEARREGULATORY COHHISSION LICENSEEEVENTREPORT(LER)TEXTCONTINUATION PROVEDBYOHBNO.3150~0104EXPIRES5/31/95ESTIMATED BURDENPERRESPONSETOCOMPLYWITHTHISINFORMATION COLLEC'TION REOUEST:50.0HRS.FORWARDCOMHENTSREGARDING BURDENESTIHATETOTHEINFORMATION ANDRECORDSMANAGEMENT BRANCH(MNBB7714),U.S.NUCLEARREGULATORY COHHISSION, WASHINGTON, DC20555-0001, AHDTOTHEPAPERWORK REDUCTION PROJECT(3150.0104),

OFFICEOFMANAGEHENT ANDBUDGETWASHINGTON DC20503.FACILITYNAHE(1)R.E.GinnaNuclearPowerPlantDOCKETNUMBER(2)05000244LERNUMBER(6)SEOUENTIAL 95--001--REVISION00PAGE(3)4OF9TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366A)(17)The"as-found" setpoints were1.6%(forV-434)and2.3%(forV-435)above2485psig.ThisiscontrarytoGinnaTechnical Specification 3.1.1.3.c, whichstates,"Whenever thereactorisatoraboveanRCStemperature of350degreesF,bothpressurizer codesafetyvalvesshallbeoperablewithaliftsettingof2485psig+/-1%."Aconservative decisionwasmadetoreportthiseventunderthecriteriaof10CFR50.72(b)(2)(iii)(D),basedoninputfromNS&Lthata+/-1%tolerance forsafetyvalveactuation isanassumption forseveraldesignbasisevents.TheNRCwasnotifiedatapproximately 2011ESTonFebruary3.Subsequent evaluations havenotbeenabletoconclusively determine thetimethatthesetpointshiftoccurred, noreveniftheshiftoccurredduringcycle23.Reviewofdesignbasiseventshasconfirmed thatthiscondition doesnotmeetthereporting criteriaof10CFR50.72.INOPERABLE STRUCTURES, COMPONENTS, ORSYSTEMSTHATCONTRIBUTED TOTHEEVENT:NoneD.OTHERSYSTEMSORSECONDARY FUNCTIONS AFFECTED:

NoneMETHODOFDISCOVERY:

RG&EQASurveillance ofthetestdataidentified thatthetestresultswereunacceptable.

Thisinformation

'wasforwarded toNES,andNCR95-005wasinitiated.

DuringareviewofthisNCRbetweenNESandSystemEngineering, thiscondition wasevaluated aspotentially reportable.

HRCFORH366A(5-92)

NRCFORM366A(5-92>U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)DOCKETNUMBER(2)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION PPROVEDBYOHBNO.3150.0104 EXPIRES5/31/95ESTIMATED BURDENPERRESPONSETOCOMPLYWITHTHISINFORMATION COLLECTION REOUEST:50'NRS.FORWARDCOHHENTSREGARDIHG BURDENESTIHATETOTHEINFORMATION ANDRECORDSMANAGEMENT BRANCH(HNBB7714),U.S.NUCLEARREGULATORY COMHISSION, WASHINGTON, DC20555-0001 ANDTOTHEPAPERWORK REDUCTION PROJECT(31400104>,OFFICEOFMANAGEMENT ANDBUDGETWASHINGTON DC20503.PAGE(3)LERNUHBER(6)R.E.GinnaNuclearPowerPlant05000244YEAR9500100SEOUENTIAL REVISION5OF9TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366A)(17)F.OPERATORACTION:TheSystemEngineernotifiedtheShiftSupervisor ofthetestresultsthataffectedbothPRZRsafetyvalvesthatwerepreviously installed andconsidered operableduringcycle23,andthattheseresultsdidnotaffectcurrently installed equipment.

AdecisionwasmadetonotifytheNRCper10CFR50.72(b)(2)(iii)(D).Thisnotification wasmadeatapproximately 2011ESTonFebruary3,1995.Sincethiseventdidnotaffectinstalled plantequipment, nootheroperator, actionswerenecessary.

SAFETYSYSTEMRESPONSES:

NoneIII.CAUSEOFEVENT:IMMEDIATE CAUSE:Theimmediate causeforbothPRZRsafetyvalvesbeingconsidered inoperable wasthatthe"as-found" liftsettingsforthesevalveswereabovethesetpointtolerance ofTechnical Specification 3.1.1.3.c.

B.INTERMED1ATE CAUSE:Theintermediate causeforthe"as-found" liftsettingsabovethe'etpointtolerance ofTechnical Specifications wasashiftinthesetpoints fromthe"as-left" conditions ofMarch,1993,tothe"as-found"conditions ofJanuary,1995.NRCFORH366A(5-92>

NRCFORM366A.(5-92).S.NUCLEARREGULATORY COHHISSION LICENSEEEVENTREPORT(LER)TEXTCONTINUATION PROVEDBYOHBNO.3150.0104 EXPIRES5/31/95ESTIMATED BURDENPERRESPONSETOCOHPLYWITHTHISINFORHATION COLLECTION REQUEST:50.0NRS.FORWARDCOHHENTSREGARDING BURDEHESTIHATETOTHEINFORHATION ANDRECORDSHANAGEHENT BRANCH(HNBB7714),U.S.NUCLEARREGULATORY COHHISSIONg WASHINGTON, DC20555-0001, AHDTOTHEPAPERWORK REDUCTIOH PROJECT(3150-0104),

OFFICEOFHANAGEHENT ANDBUDGETWASHINGTON DC20503.FACILITYNAHE(1)R.E.GinnaNuclearPowerPlantDOCKETNUHBER(2)05000244YEAR95001--00LERNUHBER(6)SEQUENTIAL REVISIONPAGE(3)6OF9TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366A)(17)C.ROOTCAUSE:Theunderlying causeoftheshiftinthesetpoints isattributed toacombination offactors,including attendant variables affecting thelong-term operation ofthevalves,andthesubsequent removal,decontamination,

handling, andshippingofthevalvestoanoff-sitefacilityfortesting..

TheGinnaTechnical Specification requirements of+/-1-'.maynotbeappropriate withrespecttotheallowances fornormalsetpointshiftsduringoperation, removal,andshipping.

ThiseventisNUREG-1022 CauseCode(B),"DesignManufacturing, Construction

'/Installation."

IV.ANALYSISOFEVENT:Thiseventisreportable inaccordance with10CFR50.73,LicenseeEventReportSystem,item(a)(2)(vii)(D),whichrequiresareportof,"anyeventwhereasinglecauseorcondition causedatleastoneindependent trainorchanneltobecomeinoperable inmultiplesystemsortwoindependent trainsorchannelstobecomeinoperable inasinglesystemdesignedto...mitigatetheconsequences ofanaccident."

Bothindependent trainsofpressurereliefforthePRZRwereconsidered inoperable duetothe"as-found" liftsettingsabovethetolerance oftheTechnical Specifications.

NRCFORH366A(5-92)

NRCFORM366A(5.92).S.NUCLEARREGULATORY COMMISSION LICENSEEEVENTREPORT(LER)TEXTCONTINUATION PROVEDBYOHBNO.3150-0104 EXPIRES5/31/95ESTIMATED BURDENPERRESPONSETOCOHPLYWITHTHISINFORHATIOH COLLECTION REOUEST:50.0HRS.FORWARDCOMMENTSREGARDING BURDENESTIMATETOTHEINFORHATION AHDRECORDSMANAGEMENT BRANCH(HNBB7714),U.S.NUCLEARREGULATORY COMHISSION, WASHINGTON, DC20555-0001, AHDTOTHEPAPERWORK REDUCTION PROJECT(31500104),OFFICEOFMANAGEMENT ANDBUDGETWASHINGTON DC20503.FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKETNUHBER(2)05000244LERNUMBER(6)SEOUENTIAL95--001--REVISION00PAGE(3)7OF9TEXT(Ifmorespaceisrequired, useadditional copiesofHRCForm366A)(17)Thetwolimitingdesignbasiseventsthatchallenge reactorcoolantsystem(RCS)integrity andrelyonthePRZRsafetyvalvestomitigatetheirconsequences aretheLockedRotortransient andtheLossofLoadtransients Thesetransients werereanalyzed

.byWestinghouse onbehalfofRG&E.kAnassessment wasperformed considering boththesafetyconsequences andimplications ofthiseventwiththefollowing resultsandconclusions:

~Thesetpoints forthePRZRsafetyvalvesshiftedatsomeunknowntimebetweenMarch,1993,andJanuary,1995.Thiscondition didnotcreateasignificant safetyhazardforthefollowing reasons:1.Whilethevalveswouldhavebeendeclaredinoperable (hadthecondition beenknown)basedontheTechnical Specification tolerance, thereanalyses ofthetwolimitingtransients showsthatifthevalveshadliftedatthe"as-found" pressureduringadesignbasisevent,theywouldhaveperformed theirdesignfunctionwithacceptable results.Thus,theacceptance criteriaofallUFSARChapter15designbasiseventswouldstillbesatisfied.

2.Thedesignbasisconditions boundtheactualconditions thatexistedduringcycle23.Factorsthatwouldhavemadethelimitingeventslesssevereare:(a)Steady-state reactorpowerwasapproximately 98%duringcycle23,versusthedesigncondition of100'%b)The"as-found" setpoints wereboundedbytheWestinghouse reanalysis assumptions forthesetpointtolerance.

~NoeventthatwouldhaverequiredPRZRsafetyvalveactuation occurredduringcycle23.Therewerenooperational orsafetyconsequences orimplications attributed totheshiftinliftsetpoints, becausealltherequiredRCSpressurelimitations weremet,usingthe"as-found" setpoints.

Basedontheabove,itcanbeconcluded thatthepublic'shealthandsafetywasassuredatalltimes.HRCFORH366A(5-92)

NRCFORH366A(5-92).S.NUCLEARREGULATORY COMMISSION LICENSEEEVENTREPORT(LER)TEXTCONTINUATION PROVEOBYOHBNO.3150~0104EXPIRES5/31/95ESTIMATED BURDENPERRESPONSETOCOMPLYWITHTHISINFORHATION COLLECTION REQUEST:50.0HRS.FORWARDCOMMENTSREGARDING BURDENESTIMATETOTHEIHFORHATIOH ANDRECORDSHANAGEHENT BRANCH(MNBB7714),U.S.NUCLEARREGULATORY COHMISSION, WASHINGTON, DC20555-0001, AHDTOTHEPAPERWORK REDUCTION PROJECT(3150-0104),

OFFICEOFMANAGEMENT ANDBUDGETWASHINGTON DC20503.FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKETNUHBER(2)05000244YEAR95LERNUMBER(6)SEQUENTIAL

--001--REVISIONM00PAGE(3)8OF9TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366A)(17)V~A.CORRECTIVE ACTION:ACTIONTAKENTORETURNAFFECTEDSYSTEMSTOPRE-EVENT NORMALSTATUS:~Thevalveseatswerelappedandthevalvesadjustedasnecessary tobringtheliftsettingsintoconformance withtheTechnical Specifications tolerance.

~TheaccidentanalysesthatareaffectedbyaPRZRsafetyvalvewithalargertolerance thanrequiredbyTechnical Specification 3.1.1.3.c havebeenreanalyzed byWestinghouse.

Theresultsarethatthefunctions ofthePRZRsafetyvalveswereneverunacceptable withthe"as-found" liftsettings.

B.ACTIONTAKENORPLANNEDTOPREVENTRECURRENCE:

Basedontheresultsoftheaccidentreanalysis, arevisiontotheTechnical Specifications toprovidemorerealistic andachievable liftsettingtolerances andacceptance criteriaforoperability willbepursuedonaprioritybasis,aspartoftheRG&EiNRCefforttoimplement theImprovedTechnical Specifications (ITS).Tominimizethechanceofashiftinthesetpointduetoactivities associated withon-siteremoval,handling, decontamination, packaging,

shipping, storing,andreinstallation, theadministrative controlsforremoval,shipping, testing,andreinstallation ofthesevalveswillbeevaluated andenhanced, asappropriate, toensurethatpropercontrolsareinplaceforkeyactivities thatcouldinadvertently affecttheliftsettings.

Toincreasetherepeatability oftestresults,NESwillevaluatetheadequacyofthetestrequirements ofMET-049,andrevisethetestspecification, asappropriate.

NRCFORH366A(5-92)

NRCFORM366A(5-92).S.NUCLEARREGULATORY COHHISSION LICENSEEEVENTREPORT(LER)TEXTCONTINUATION PROVEDBYOHBNO.3150~0104EXPIRES5/31/95ESTIHATED BURDENPERRESPONSETOCOMPLYWITHTHISINFORMATION COLLECTION REQUEST:50.0HRS.FORWARDCOMMENTSREGARDING BURDENESTIMATETOTHEINFORHATION ANDRECORDSMANAGEMENT BRANCH(MNBB7714),U.S.NUCLEARREGULATORY COMMISSION, WASHINGTON, DC20555-0001 ANDTOTHEPAPERWORK REDUCTION PROJECT(31/0-0104),

OFFICEOFMANAGEHENT ANDBUDGETWASHINGTON DC20503.FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKETNUMBER(2)050002449500100LERNUHBER(6)YEARSEQUENTIAL REVISIONPAGE(3)9OF9TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366A)(17)VI.ADDITIONAL INFORMATION:

A.FAILEDCOMPONENTS:

Thefailedcomponents areCrosbyValveandGageCo.safetyvalves,ModelHB-BP-86E, serialnumbersN69877-00-0006 andN69877-00-0007.

PREVIOUSLERsONSIMILAREVENTS:AsimilarLEReventhistorical searchwasconducted withthefollowing results:Nodocumentation ofsimilarLEReventswiththesamerootcauseatGinnaNuclearPowerPlantcouldbeidentified.

C.SPECIALCOMMENTS:

NoneNRCFORH366A(5-92)