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LER-2093-010,
Event date:
Report date:
	2542093010R00 - NRC Website
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LER 93-010-00:on 930720,HPCI Declared Inoperable & HPCI Outage Rept Qcos 2300-2 Initiated Because IST Flow Rate Fell in IST Required Action Range Due to New Procedure. Surveillance Procedure Will Be revised.W/930819 Ltr
	ML20056E435
Person / Time
Site:	Quad Cities
Issue date:	08/19/1993
From:	Bax R, Radloff N; COMMONWEALTH EDISON CO.
To:	; NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM)
References
	LER-93-010-04, LER-93-10-4, RLB-93-113, NUDOCS 9308240039
	Download: ML20056E435 (7)
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.

. Commenw::cith Edison CO Ouad Cities Nuclear Power Station

, Gy 22710 206 Avenue North Cordova, Illinors 61242-9740 Te6ephone 309!654 2241 i RLB-93-ll3 August 19, 1993 U.S. Nuclear Regulatory Commission Document Control Desk Washington, DC 20555

Reference:

Quad Cities Nuclear Power Station Docket Number 50-254, DPR-29, Unit One Enclosed is Licensee Event Report (LER) 93-10, Revision 00, for Quad Cities Nuclear Power Station.

This report is submitted in accordance with the requirements of the Code of Federal Regulations, Title 10, Part 50.73(a)(2)(v)(D). The licensee shall report any event or condition that alone could have prevented the fulfillment i of the safety function of structures or systems that are needed to mitigate ,

the consequences of an accident.

Respectfully, COMMONWEALTH EDIS0N COMPANY QUA, CITIES NUCLEAR POWER STATION b

. L. Bax Station Manager RLB/TB/p1m Enclosure cc: J. Schrage T. Taylor INP0 Records Center NRC Region III C400: 4 STMGR(11393.RLB 9308240039 930819 [ g \

FDR ADOCK 05000254 L \

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LICENSEE EVENT REPORT (LER) Form Rev. 2.0 F6cdny 54ame (1) Docket Number (2) Page (3)

Quad Cities Unit One 0 p p p p p p p 1 Mp p Title (4)

U l HPCIInop Due To IST Flow in Required Action Range During QCOS 2300-5 Event Date (5) LER Number (6) Report Date (73 Other Facilitsea involved (8)

Month Day Year Year Sequential Revision Month Day Year Facilay DocLet Number (s)

Number Number Names .

o P P P P I I I 0 [7 2 p 9 l3 9 p -

O p p -

O p 0 p i p 9 p 0 p p p p l l l OPEJLATING THIS REPORT 15 $UhMrITED PURSU ANT TO THE R WUIRDtENTS OF 10CFR MODE (9) (Check one or more of the following) (1i) 3 20.402(b) 20.40$(c) 50.73(a)(2)(ev) 73.71(b) power 20.405(a)(1)G) 50.36(c)(1) T50.73(a)(2)(v) -73.71(c)

LEVEL 20.405(a)(1)0i) 50.36(c)(2) 50.73(a)(2)(vii) Other (Specify 9 20.405(a)(1)Gii) 50.73(a)(2)0) 50.73(a)(2)(viii)(A) in Abstract (10) 0 l0l below and in 20.405(a)(1)0v) 50.73(a)(2)Si) 50.73(a)(2)(viii)(B) 20.405(a)(1)(v) 50.73(a)(2)Gii) 50.73(a)(2)(x) Text)

LICENSEE CONT ACT FOR THis LER (11) .

NAME TELEPHONE NUMBER AREA CODE Nick Radloff, HPCI System Engineer. Ext. 2942 3 p p 6 p p l-p p pp COMPLETE ONE LINE FOR EACH COMPONENT F AILURE DESCRihED IN THIS REPORT (13)

CAUSE SYSTDi COMPONENT M AN UF ACTURER REPORTABLE CAUSE SYSTEM COMPONENT M AN UF ACTURER REJaORTAbil TO NPRDS TO NPRDS i

D 813 I I I I I i N l l l l l l l I I I I I i I I I I I I I SUPPLEMEN"I AL REPOKI EXPECTED (14) Expected Month Day Year i Submission l

]YES (If yes, complete EXPECTED SUBMISSION DATE) 70 Date (15) l l l ;

i ABSTRACT (lamat to 1400 spacca,i.e., approximately fifteen amgle-space typewnnen Ames) (16) l l

ABSTRACT:

i At 2122 hours0.0246 days 0.589 hours 0.00351 weeks 8.07421e-4 months on July 20, 1993, Unit One was in the Startup mode at 9 percent of rated !

core thermal power. At this time, the NSO was performing the IST portion of IP-193, HPCI Periodic and Quarterly Pump Operability Test. During this test, the HPCI pump achieved approximately 4890 gpm at 1255 psig and 3700 rpm's. The IST acceptable range for the pump is between 5123-5559 gpm at 1255 psig pump discharge pressure and 3800 rpm's. Because the flow rate fell in the IST required action range, the Shift Engineer declared HPCI inoperable and initiated QCOS 2300-2, HPCI Outage Report.

l The cause of this event was due to a new procedure. A contributing factor to this event was the 1-2358 FT, HPCI flow transmitter.

Corrective actions will include revising the surveillance procedure to ensure the MSC is at the HSS during IST testing of the HPCI system and calibrating the HPCI square root convertor every cycle.

This report is being submitted to comply with 10CFR50(a)(2)(v)(D).

LER254\93\010.%TF

LICENSEE EVENT REPORT (LER) TEXT CONTINUATIO95 Form Rev. 2.0 F AC11JTY N AMF 0) DOCKEI NUMBER (2) LDL NUMBER (b) PAGE (3) ;

Year sequentia! Revision Number Number ,

quad Cities Unit One O p p p p p p p 9 p 0 p p -

O p 2 pF p l6 TEXT Energy Industry identificauon System (Ells) codes are identified m the text as [XXJ PLANT AND SYSTEM IDENTIFICATION:

General Electric - Boiling Water Reactor - 2511 MWt rated core thermal power.

EVENT IDENTIFICATION:

A. CONDITIONS PRIOR TO EVENT:

Unit: One Event Date: July 20, 1993 Event Time: 2122 hours0.0246 days 0.589 hours 0.00351 weeks 8.07421e-4 months Reactor Mode: Startup (3) Mode Name: Startup Power Level: 9%

This report was initiated by Licensee Report 254\93-010.

STARTUP (3) - In this position, the reactor protection scram trips, initiated by condenser low vacuum and main steamline isolation valve closure are bypassed, the low 4 pressure main steamline isolation valve closure trip is bypassed and the reactor l protection system is energized, with IRM and APRM neutron monitoring system trips and j control rod withdrawal interlocks in service.

B. DESCRIPTION OF EVENT: l At 2122 hours0.0246 days 0.589 hours 0.00351 weeks 8.07421e-4 months on July 20, 1993, Unit One was in the Startup mode at 9 percent of i rated core thermal power. At this time, the Unit One Nuclear Station Operator (NS0) was performing the In-Service Testing (IST) portion of Interim Procedure (IP) 193, High Pressure Coolant Injection (HPCI)[BJ] Periodic and Quarterly Pump Operability Test. During this test, the HPCI pump [P] achieved approximately 4890 gallons per minute (gpm) at 1255 pounds per square inch gage (psig) and 3700 revolutions per l minute (rpm). The IST acceptable range for the pump is between 5123-5559 gpm at 1255 ;

psig pump discharge pressure and 3800 rpm's. Because the flow rate fell in the IST !

required action range, the Shift Engineer declared HPCI inoperable and initiated QCOS '

2300-2, HPCI Outage Report. I The IST testing portion of the surveillance requires measuring pump flow at a j constant pump speed and differential pressure across the pump. The results are compared against baseline data to detect any changes in system performance.

l At 2200 hours0.0255 days 0.611 hours 0.00364 weeks 8.371e-4 months on July 20, 1993, the NRC was notified of the event via the Emergency Notification System in order to comply with the requirements of 10CFR50.72(b)(2)(iii)(D).

Instrument Maintenance (IM) personnel were notified due to possible drift in the flow control loop. Nuclear Work Request (NWR) #Q08740 was initiated to calibrate the flow control loop.

LER254\93\010.%TF I

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i i

LICENSEE EVENT REPORT (LER) TEXT CONTINUATION Form Rev. 2.0 i FACILTTY NAML(1) DOCKET SUMitLR (2) LER NUMBEJt (6) PAGE (3) ;

Year Sequenual Revision Number Number .

Quad Cities Umt one 0 p p p p p p p 9 p -

0 p p 0 p 3 pF p l6 1Erl Energy irrJustry idenuficauon System (Lil5) codes are idenufied in the text as (XX) i

At 2110 hours0.0244 days 0.586 hours 0.00349 weeks 8.02855e-4 months on July 21, 1993, IM personnel had completed their calibration of the

flow control loop. They discovered air was trapped in the high side instrument line of the flow transmitter [ FIT] which could affect the flow transmitter output signal.

The transmitter was found to be within acceptable tolerances. The flow controller and square root convertor were also found to be within acceptable tolerances.

At 2140 hours0.0248 days 0.594 hours 0.00354 weeks 8.1427e-4 months , IP 193 was performed again. The IST pump data was 5170 gpm at 1255 psig pump discharge pressure, thus falling into the acceptable range. Discussions L ensued and was determined the system would be tested again for repeatability.

4 At 0800 hours0.00926 days 0.222 hours 0.00132 weeks 3.044e-4 months on July 22, 1993, the Nuclear Station Operator (NS0) noticed the 1-2340-1 FIC, HPCI flow controller [FIC], indicating approximately 190 gpm in normal

! standby lineup. IM personnel were contacted.

IM's found the flow transmitter zero had shifted. After extensive troubleshooting, it .

was determined after the flow transmitter housing was removed for calibration, the HPCI Room Cooler fan blew air on the balance bar of the tranistter causing an e incorrect calibration of the transmitter. The ir flow was blocked so it would not be i directed on the flow transmitter balance bar. IM personnel calibrated the flow transmitter again.

At 1640 hours0.019 days 0.456 hours 0.00271 weeks 6.2402e-4 months , HPCI was run again. The system engineer and IM personnel were in the !

control room to observe the flow controller's response. A General Electric (GE) field engineer was down in the HPCI room to observe the governor controls. The IST .

data was 4450 gpm at 1250 psig pump discharge pressure and 3690 rpm's. During the test, the GE field engineer noticed that the HPCI Motor Speed Changer (MSC) [SC]was at the electrical High Speed Stop (HSS), but had not reached the mechanical HSS. He immediately reported this to the system engineer and Operating. The system engineer i and Operating discussed the finding and had the field engineer manually raise the MSC !

approximately 3/8 of a turn to the mechanical HSS using the MSC handwheel stem. The pump flow increased to 5270 gpm. The MSC was cycled a couple of times using the MSC control switch from the control room. The NSO held the control switch in the slow i raise position approximately 15 seconds after the electrical HSS light indication .

pick.ed up. The flow consistantly returned to approximately 5270 gpm. HPCI was i i shutdown.

Discussions ensued and it was determined that during the startup of the turbine, the !

procedure directs the NSO to increase the turbine speed by taking the MSC to the HSS ;

observing the light indication. Although the MSC was at the electrical HSS, its ,

possible the MSC was not at its mechanical HSS. It was decided to adjust the MSC and i MGU HSS limit settings to provide a more accurate indication to the NSO when the MSC

was at the mechanical HSS. NWR #Q08761 was initiated to adjust the HPCI limit switch

, controls. It was also determined the MSC electrical HSS limit switches would not have affected operability of the system and that if the MSC was at the mechanical HSS during the first test run, it would have passed the IST requirements.

At 0120 hours0.00139 days 0.0333 hours 1.984127e-4 weeks 4.566e-5 months on July 23, 1993, Electrical Maintenance (EM) personnel had finishec adjusting the HPCI governor controls and Operating prepared to run HPCI again.

l LER254i93\010.%7F v

i LICENSEE EVENT REPORT (IIR) TEXT CONTINU ATION Form Rev. 2.0 FACILITY N AME (1) DOCKET NUMBER GJ LER NUMBER (6) PAGE 0)

Year $cquennal Revision ;

Number Numtwr l Quad Ciues Urut One O p p p p p p p 9 p 0 $ p -

0 p 4 pF p p TLXT Ermrgy Industry idenuficauon system (L115) codes a-c idenufied in the text as [XXJ During the surveillance, the pump achieved 5620 gpm flow at 1255 psig pump discharge pressure and 4020 rpm's. The rest of the surveillance was completed successfully.

It was decided to run HPCI again to ensure consistant data for IST requirements. l At 1700 hours0.0197 days 0.472 hours 0.00281 weeks 6.4685e-4 months , HPCI was run again with the same results as before. Because the HPCI controls were adjusted, new IST baseline data was established. The rest of the surveillance was completed successfully. The SE declared HPCI operable and

, terminated the outage report. l C. APPARENT CAUSE OF EVENT: ,

This report is being submitted to comply with 10CFR50.73(a)(2)(v)(D) which requires ;

~

the licensee report any event or condition that alone could have prevented the fulfillment of the safety function of systems that are needed to mitigate the consequences of an accident. i The cause of this event was due to a new procedure. IP-193 tests the HPCI system ,

using the MSC control switch in " Slow Raise" to manually startup the turbine and bring it up to operating speed. The procedure steps directs the Operator to keep raising the MSC until the HSS light indication is received in the control room. The !

slow raise of the MSC allows the MSC to pickup the limit switches quick enough to f stop short of the mechanical HSS, thus not allowing the system to achieve full .

operating speed. Because the MSC was not at its mechanical HSS, turbine speed was !

reduced enough to create a low flow condition. j

't Investigation into this event revealed other contributing factors affecting the flow !

controller's indication. The 1-2358 FT, HPCI flow transmitter had some air trapped in the instrument line. The drift in the transmitter caused the flow controller reading to be approximately 120 gpm lower than actual flow. This alone would not ,

have been able to cause a failure with the surveillance test due to the drift still ;

being within allowable tolerances. l I

After the flow transmitter was calibrated, the drift in the flow controller in standby mode was due to an inaccurate calibration of the flow transmitter created from the air turbulence within the HPCI room. The flow transmitter balance bar was in the direct flow path of the HPCI room cooler fan causing an inaccurate calibration.

D. SAFETY ANALYSIS OF EVENT:

The safety of the plant and personnel was not affected in this event. Per Technical Specification 3.5.C.2, if the HPCI subsystem is inoperable, reactor operation is allowed for fourteen days provided all active components of the Automatic Pressure Relief (APR) subsystems, the Core Spray (CS) subsystems, and Low Pressure Coolant Injection (LPCI) mode of Residual Heat Removal (RHR) system are operable. These systems were operable throughout this event.

LER254\9h010.WPF

e LICENSEE EVENT REFORT (LER) TEXT CONrINUATION Form Rev. 2.o FACILITY NAME(1) DOCKET N UMBER (2) LEJL NUMBER (6) PAGE (3)

Year Sequennal Revision Nmder Nurder Qind Cities Unit One O p p p p p p p 9 p -

O p p -

O p 5 pF p l6 TEXT Energy industry idenuficeuon system (Ells) codes are idenufied in the text as [XXj HPCI would still have fulfilled its intended safety function. During an auto-initiation signal, the MSC controls the startup ramp of the turbine. 1he MSC will run from the LSS to the mechanical HSS in " Fast Raise" mode and will remain at the mechanical HSS. The MSC HSS limit switch indicating light does not affect the operation of the MSC.

E. CORRECTIVE ACTIONS:

The immediate corrective actions consisted of declaring HPCI inoperable and initiating the HPCI system outage report and NWR #Q08740.

The surveillance procedure will be revised to ensure the MSC is at the HSS during IST testing of the HPCI system (NTS# 2541809301001).

After troubleshooting the flow control loop, IM personnel calibrated the flow transmitter, flow controller, and square root convertor. IM personnel will incorporate procedural guidance in their flow transmitter calibration procedures to ensure no fans or any other air moving devices are operating during instrument calibrations where the air turbulence can affect the instrument calibration (NTS# 2541809301002).

The HPCI square root convertor will be cal'brated once a cycle to ensure no drift occurs in the instrument (NTS# 2541809301003).

EM personnel readjusted the mechanical and electrical MSC HSS to allow the system to operate more closely to its designed flowrate and speed.

F. PREVIOUS EVENTS:

A search of previous License Event Reports (LER) and Deviation Reports (DVR) over the last five years has identified multiple LER's involving problems with IST testing, however, there were no similar events identifying MSC HSS control problems. Some of the LER's involving IST t; sting are listed below:

D-4-1-90-110 HPCI inoperable due to high flow during IST portion of QCOS 2300-5 D-4-2-91-043 HPCI pump operability IST data fell into required action range due to unknown causes D-4-1-91-132 RCIC inoperable due to high pump flow D-4-2-91-024 2C RHR pump declared inoperable for high flow due to procedural deficiencies D-4-2-90-041 2D RHR pump declared inoperable due to incorrect reference value LER254\93\010.WPF

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LICENSEE EVENT REPORT (LER) TEXT COffrINUATION Form Rev. 2.0 FACILITY NAME (1) DOCK 13 NUMhEJt (2) LUt NUMBut t6) PAGE (3)

Year Sequenual Revision Number Noneer

@od Citie: Unit one O p pp p p p l4 9 p -

O p p -

O p 6 pF p p TEXT Emergy Induary kiemaficeuon System (Uli) codes are idenufied in the text as {XXj A Nuclear Plant Reliability Data System (NPRDS) search was not conducted due to no -

failed component was identified during this event.

G. CMPONENT FAILURE:

There was no failed component identified during this event.

I e

LER254\93\010.%TF ,

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