ML18036A673
| ML18036A673 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 02/05/2018 |
| From: | Ameren Missouri, Union Electric Co |
| To: | Office of Nuclear Reactor Regulation |
| Shared Package | |
| ML18036A667 | List:
|
| References | |
| ULNRC-06410 | |
| Download: ML18036A673 (11) | |
Text
ENCLOSURE 4 RESPONSE TO REQUEST FOR ADDITIONAL INFORMATION (RAI) 1 .d (MOV Performance Indicator Report for Cycle 19) to ULNRC-06410 Page 1 of 10 NET 13-0064 October 21, 2013 To: Greg Kremer Victor Thomas from: Mike Brenner Re: MOV Testing Program The attached 1$ Month MOV Performance Indicator Report for Cycle 19 was prepared in accordance with the provisions of EDP-ZZ-0 1114, Motor Operated Valve Program Guide.
Key Accomplishments:
All of Callaways safety-related Motor Operated Valves (MOV) are properly set up and are in good working condition. There are no signs of adverse trends. Nominal operating parameters are documented in Attachment 2.
a) All rising stem MOVs with active safety related functions using a torque switch in their closing stroke are setup to exceed the 25% target margin. Having 25%
margin allows a 4-cycle/6 year static testing (rather than DP testing) interval for periodic verification of operability.
b) All rising stem MOVs with active safety function using a limit switch to open and or close have positive margin.
c) All butterfly MOVs have had their torque switches jumpered or removed. These MOVs must have positive margin for opening and closing stroke with an active safety-related function. All butterfly MOVs meet the parameters required to: I) eliminate the need for periodic differential pressure testing, and 2) utilize the 4 cycle/6 year interval for periodic verification of operability.
- The results of testing performed on rising stem valves during cycle 19 confirms that there is no lubrication degradation of the stem-to-stem nut interface over the 18-month interval between maintenance.
Page 1 of2 to ULNRC-06410 Page 2 of 10 Planned Enhancements
- Continued utilization of the CRANE Easy Torque/Thrust Sensor (ETT). The ETT is a permanently mounted stem strain gauge used for direct measurement of torque and thrust. It is planned to use ETTs on MOV butterfly valves in preparation for testing MOVs at the Motor Control Center (MCC).
- Revise calculation ZZ-536 or create a new calculation to calculate capability and margin for MOVs utilizing EPRI PPM.
- If resources are available, continue work on the development of testing MOVs at their Motor Control Center (MCC).
Michael E. Brenner MOV Engineer Attachment 1: 18 Month MOV Performance Indicator Report for Cycle 19 Attachment 2: Database for Cycle 19 with Margins and Limits cc: file: A160.0446 Greg Kremer Victor Thomas Mike Brenner Darrel Heckel Curtis Wood Page 2 of 2 to ULNRC-06410 Page 3 of 10 Attachment 1 18 Month MDV Performance Indicator Report For Cycle 19 This report provides an overview of the performance and condition of all safety related motor-operated valves (MOVs) in the OL 89-10 Program at the Callaway plant and recaps MOV Program activities over Cycle 19 and Refuel 19 (11/25/11 to 5/28/13),
in accordance with the provisions of EDP-ZZ-0 1114, Motor Operated Valve Program Guide.
The 18 Month MOV Performance Indicator Report is broken down into seven main sections:
- 1. Summary of Diagnostic Testing Performed to Date and a Recap of Testing Performed during the past 18 Months
- 2. Description of the Current Set-Up of all Safety-Related MOVs
- 3. Description of Major Work Completed on Safety-Related MOVs
- 4. Summary of Adverse Condition CARS issued on Safety-Related MOVs
- 5. Summary of Trends Identified from Test Results
- 6. Actions to Improve Margin and Reduced Voltage Performance
- 7. Planned Actions to Enhance the Callaway MOV Program.
Page 1 o18 to ULNRC-06410 Page 4 of 10 Attachment 1 18 Month MQV Performance Indicator Report For Cycle 19
- 1. Summary of Diagnostic Testing Performed to Date and a Recap of Testing Performed during the Past 18 Months:
There are currently 144 valves in the Motor-Operated Valve (MOV) program. All 144 MOVs have been Baseline tested and 99 have been Differential Pressure (DP) tested.
for Cycle 19, Periodic Verification Tests were performed on 45 MOVs. The MOV component ID and test date are listed below.
MOV Component Description Test Date ID ALHV0007 MDAFP TO S/G B HV 10/18/2012 ALHVOO3O ESWTOMDAFPBHV 10/18/2012 ALHVOO36 CST TO TD AFP HV 05/18/2013 RCP A THRM BAR COOL COIL COOL WTR BBHVOO13 OUT HV 05/05/2013 RCP B THRM BAR COOL COIL COOL WTR 33HV0014 OUT HV 05/05/2013 RCP C THRM BAR COOL COIL COOL WTR BBHVOO15 OUTHV 05/05/2013 RCP D THRM BAR COOL COIL COOL WTR BBHVOO16 OUT HV 05/05/20 13 BBHV$000B RCS PZR OUT PWR OPER RLF HV 04/27/20 13 RCS PRT OUT TO CTMT NORM SMP ISO BBHV8O37B HV 04/20/2013 RCS LOOP 1 HOT LEG TO RHR PMPS PCV BBPV87O2A ISO 05/05/2013 RCS LOOP 4 HOT LEG TO RHR PMPS PCV BBPV$7023 ISO 04/20/2013 BGHV8 100 SEAL WTR RIN OUTER CTMT ISO 04/17/20 13 CVCS CHARGING HDR TO REGEN HX BGHV8 106 OUTER CTMT ISO VLV 04/28/20 13 A CC? DISCH MINIFLOW TO SEAL WTR BGHV811O HXISO 04/17/2012 BNHV0003 RWST TO CTMT SPRY PM? B HV 03/06/2013 Page 2 of 8 to ULNRC-06410 Page 5 of 10 Attachment 1 18 Month MOV Performance Indicator Report For Cycle 19 FUEL POOL FIX B SHELL SIDE CCW OUT ECHVOO12 ISO 07/23/2012 EfFW0024 SERV WTR TO ESW TRN B UPSTRM HV 04/02/2013 EFHVOO25 SERV WTR TO ESW TRN A DNSTRM HV 0 1/15/2013 EFHVOO39 ESW TRN A TO SERV WTR UPSTRM IiV 01/16/2013 EFHVOO4O ESW TRN B TO SERV WTR UPSTRM 1 1/20/20 12 ESW UHS COOL TOWER TRN B BYP HAND 04/24/20 13 EFHVOO66 CTRL VLV EFPDVOO19 ESW S-C STR A DRN DP CTRL VLV 05/04/20 13 EGHVOO15 CCW TRI1 A SPLY/RTN ISO HV 05/06/2013 EGHVOO53 CCW TRN A SPLY ISO HV 05/16/20 13 EGHVOO5$ CCW TO RCS CTMT OUTER ISO FW 04/27/20 13 EGHVOO62 CCW FROM RCS IN CTMT ISO liv 04/17/20 13 EGHVO127 CCW TO CTMT BYP ISO HV 04/19/2013 CCW FROM RCS CTMT EG-HV-0061 BYP EGHVO133 ISO HAND CTRL VLV 04/25)2013 EJHV87OYA RHR PUMP A SUCT ISO 05/01/2013 EJHV$701B RHR PUMP B SUCT ISO 04/16/2013 EJHV88O4B RHR TRN B SI PUMPS $PLY ISO 05/22/2013 BORON INJ HDR OUT ISO HAND CTRL EIvil-1V88013 VLVB 04/26/2013 EIvff{V8802A SI PMP A DISCH TO HOT LEG INJ ISO (3.0.3) 04/30/20 13 EMHV88O3A BORON [NJ HDR SPLY FROM CCP A ISO 04/26/2013 EMHV$803B BORON [NJ HDR SPLY FROM CCP B ISO 04/26/2013 RHR HX A TO SI PMPS SUCT DNSTRM ISO EMIW8807A VLVA 05/06/2013 EMHV8821B SI PMP B DISCH TO COLD LEG [NJ ISO 04/19/2019 EMHV89233 RWST TO SI PMP 3 SUCT ISO liv 04/19/2019 CTMT RECIRC SMP TO CTMT SPRY PMP A ENHV0001 HV 04/29/2013 ENHVOO12 CTMT SPRY PMP B DISCH HV 04/17/2013 EPHV88O8D SI ACC TK C OUT ISO 04/21/2013 Page 3 of $
to ULNRC-06410 Page 6 of 10 Attachment 1 18 Month MOV Performance Indicator Report For Cycle 19 AFP TURB MECH TRIP/THROT HAND CTRL FCHVO312 VLV 05/09/2013 GSHVOO21 H2 PURGE OUTER CTMT ISO RV 05/09/20 13 F-PROT LOOP TO RX BLD OUTER CTMT KCHVO253 DNSTRM ISO 05/09/20 13 CTMT NORM SMP PMPS DISCH HDR CTMT LfHVO1O5 FV 01/18/2013 Test Descriptions:
- A Periodic Verification Test (PVT) is performed to monitor performance parameter changes from the Baseline Test. PVTs are performed to verify the condition of the MOV and to validate that preventive maintenance between tests is adequate. Periodic Verification Tests are performed every four cycles or four refuels. This testing satisfies commftrnents in answering Generic Letters (GL) 89-10 and GL 96-05.
A Baseline Test is performed during or immediately after Design Basis Verification DP testing. This testing ensures that the MOV is setup to perform its safety-related functions under design basis conditions. A Calibration/Correlation between traces such as the Torque Thrust Cell (TTC) to the Optical Displacement Measurement Transducer (ODMT) is performed during the Baseline Test.
- Packing Load Tests are utilized as the retest following packing replacements or adjustments. The Packing Load Test is performed to verify that the installed packing load is less than the bounding value used in the Motor-Operated Valve Capability and Margin Calculation.
- 2. Description of the Current Set-Up of all Safety-Related MOVs:
Attachment 2 provides a synopsis of the current set-up of 29-10 Program MOVs.
Callaways commitment is to maintain a 25% torque/thrust field margin for MOVs using a torque switch to control the closing stroke and a positive field margin for MOVs using a limit switch to control the opening and closing strokes. The commitment on these MOVs is to maintain positive field margin. These commitments apply only to GL 89-10 MOVs with strokes that have a safety-related function to open, close or both.
At the end of Cycle 19:
Page 4 of 8 to ULNRC-06410 Page 7 of 10 Attachment 1 18 Month MOV Performance Indicator Report For Cycle 19 All rising-stem torque-controlled MOVs in the GL 89-10 Program with a safety function to close have a 25% or greater field margin to close and positive field margin to open
- MI rising-stem limit-controlled MOVs in the GL 89-10 Program have positive field margin for both the opening and closing strokes.
- All butterfly valve MOVs in the GL 89-10 Program meet the requirements for design basis safety-related operation having positive margin to perform their safety-related functions.
Periodic Verification Tests (PVTl 45 Periodic Verification Tests were performed during Cycle 19 as listed above.
Differential Pressure Tests (DPT:
I Differential Pressure Test was performed on FCHVO3I2.
Packing Replace or Re-torques:
46 GL 89-10 Program MOVs had packing replaced or re-torqued due to packing leaks.
Motor Pinion Inspections:
One motor pinion inspection was performed.
CAR 200302661 and ADCN 200303845 were resolved in response to 0E15680. The issue was improper staking of the key on the motor pinion gear. 129 jobs were initiated to inspect these MOVs during their scheduled Periodic Verification Test.
Inspections began in RF13 and have been completed in RF19.
Page 5 of$
to ULNRC-06410 Page 8 of 10 Attachment 1 18 Month MOV Performance Indicator Report For Cycle 19 Overall Gear Ratio (OAR) Verifications:
ADCN 200605957 documents finding an incorrect motor pinion and worm shaft gear set in EFHVOO4O. This results in a slight change in stroke time and very slight accelerated gear wear. Inspection jobs have been written on all GL 89-10 Program MOVs. 9 inspections were performed during Cycle 19. The EfHVOO42 inspection found an incorrect gear set. This was corrected and is documented in CAR 201200073.
Actuator Grease Change Outs:
3 Grease Change Outs or Actuator Rebuilds on GI 89-10 Program valves were performed during Cycle 19. Due to their work duration, these grease change outs were performed during Refuel 19. During previous Tech Spec Outages (TSO) the actuator was swapped out with a rebuilt actuator. This should be considered again.
Service and Inspects:
37 Service and Inspect PMs were performed on GL 89-10 Program MOVs. If properly aligned with Periodic Verification Tests, there should have been 45. This is a scheduling issue.
Magnesium Rotor Motor Inspection or Replacement The Nuclear Regulatory Commission (NRC) has issued two Information Notices; N 2006-26 and iN 2008-20 on Limitorque actuator motors with aluminum rotors. 26 GL 29-10 Program MOVs with magnesium rotors were identified. 14 have been replaced with aluminum rotors. There are 17 Non-safety MOVs at Callaway with magnesium rotors. 3 have been inspected and found to have motors with aluminum rotors in pristine condition. All other planned inspections have been put on budgetary hold.
Job 13000455 has been written to inspect 4 motors that were replaced. This job is Other Maintenance (OM) and has been rescheduled numerous times. If these motor inspections find no magnesium rotor degradation, all other inspection/replacement jobs will be cancelled.
MOV MCC Test Project The ability to perform motor operated valve testing from the motor control center in place of at the valve (MCC Test) is on hold. No progress has been made during Cycle
- 19. The hold is due to budget constraints. The groundwork was to be performed by Page 6 of 8 to ULNRC-06410 Page 9 of 10 Attachment 1 18 Month MOV Performance Indicator Report For Cycle 19 Crane Nuclear. It can be performed by Plant Engineering when resources are available.
MOV Component Health The MOV program overall health condition is white. This is due to slow resolution of actuator grease change out jobs due to budgetary constraints during refueling outages and the inability to perform grease change outs during TSOs.
- 4. Summary of Adverse Condition CARs issued on Safety-Related MOVs The following ADCN CARS were issued during Cycle 19. There were a total of 24 Sig 3 to Sig 6 initiated; 22 are closed and 2 are In Process.
- 201203697: fCHVO312 motor running at approximately twice normal speed A spare motor from the warehouse had internal damage resulting in it running at twice normal speed. The problem was discovered during a post maintenance test.
This is a Sig 3 ADCN CAR.
EFHVOO24 was found to have the valve uncoupled from the actuator due to coupler bolts loose. This is being resolved through a new PM or a revision to an existing PM on all applicable MOVs. This is a Sig 3 ADCN CAR.
The following are Sig 4 ADCN CARS:
- 20120108$: Update Director with Kalsi Engineering Values for Actuator Limits
- 201206217: MOVs identified with NLGI grade 3 or 4 grease with no on demand job
- 201202867: EMKV88O3A discrepancy found on OAR inspection of pinion and worm gear
- 201205940: Errors identified in Calculation ZZ-536 (Rising Stem MOV Capability [These were administrative errors; not calculation errors.]
- 201204258: Discrepancy found on MOV DP testing frequency in EDP-ZZ-0l 114
- 201208855: ZZ-212 appears to be superseded but is shown as current
- 201305543: GAPS IDENTIFIED IN MOV dip TESTiNG FREQUENCY N EDP-ZZ-01 114
- Six On-line MOV tests need to be performed by RF-19
- 201302933: Wrong worm shaft gear found installed on EFHVOO66 during rebuild Page 7 of 8 to ULNRC-06410 Page 10 of 10 Attachment 1 18 Month MOV Performance Indicator Report For Cycle 19
- 5. Summary of Trends Identified from Predictive Performance Reports:
There were no adverse trends identified following the diagnostic tests performed during the 18-month, Cycle 19 interval. Continuing favorable trends were confirmed.
- The average measured stem-to-stem nut coefficients of friction for Cycle 19 is 0.084.
- There aie no MOVs with a stemlstem nut coefficient of friction greater than the Callaway standard of 0.15. The industry bounding value for the stemlstem nut coefficient of friction is 0.20.
Cycle Average Coefficient of friction 19 0.084 18 0.084 15-17 0.085 14 0.090 13 0.091 12 0.094 11 0.092 10 0.094 9 0.095 8 0.100 7 0.104
- 6. Actions to Improve Margin and Reduced Voltage Performance:
Modification vW 0 1-1003 replaces the Motor Control Center breakers for MOVs.
With the new breakers, there is an improvement in the reduced voltage terminal voltage which improves MOV capability and margin.
- 7. Planned Actions to Enhance the Callaway MOV Program:
Motor Control Center (MCC) based MOV Diagnostic Testing The MCC based MOV diagnostic test project is stalled due to budgetary constraints.
It primary driving force was the 1ST Program update in 2014. MOV testing changes due to this update are now not required until 2024. A benefit for using the MCC Methodology is that at-valve testing could be extended to every 9 years vice every 6 years for most GL 89-10 MOVs.
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