auxiliary failed em'tt str ti - nuclear regulatory commission · facilityname (i) docket...

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REGULF. <Y INFORNATION DISTR IBUTI SYSTEM ( R IDB ) DOCKET 05000 2F cBer ACCEBBION NBR:8806080382 DOC. DATE: 88/06/03 NOTARIZED: N6 F*CIL: STN-50-528 Palo Verde Nuclear Btationr Unit 1r Ar i zona Publi AUTH. NANE AUTHOR AFF ILI AT ION SHR I VER r T. D. Arizona Nuclear Power ProJect (formerly Arizona -Public HAYNEBr J. G. Ar i zona Nuclear Power ProJect ( formerly Ari zona Public RECIP. NAME R EC I P I ENT AFF ILI*T ION SUBJECT: LER 88-013-00: on 880325r essential motor driven auxiliary feedwater pump failed to achieve rated pressurer per Tech Specs. Caused bg str ess corrosion cracking/hydrogen em'tt 1 ement. Nat 1 chang e s in i t i at e d. 4l1880325 1tT . DISTRIBUTION CODE: IE2 'D COPIEB RFCFIVED: LTR ENCL SIZE: TITLE: 50. 73 Licensee Event RepoT t (LER) r Incident Rptr etc. NOTES." Stan dar d i z ed p lan t. 0 "000.," .. REC IP IENT 'ID CODE/NANE'D5 L* LICITRAr E COP IES LTTR ENCL 1 1 1 'RECIPIENT ID CODE/NAME PD5 PD, DAVIBr N COP I ES L'TTR ENCL" 1 1 1 INTERNAL: ACRB NICHELSON AEOD/DOA AEOD/DSP/ROAB ARN/DCTB/DAB NRR/DEBT/ADB 7E NRR/DEBT/EBH SD NRR/DEBT/MEB 9H NRR/DEBT/PBH BD NRR/DEST/BGB BD NRR/DLPG/GAB 10 NRR/DREP/RAB 10 /SIB 9A 02 RES/DE/EIB RGN5 FILE 01 1 1 1 1 1 1 1 0 1 1 1 1 1 1 1 1 1 1 *1 ACRB NOELLER AEOD/DSP/NAS AEOD/DSP/TPAB DEDRO NRR/DEBT/CEB SH NRR/DEBT/ ICBB 7 NRR/DEST/NTB 9H NRR/DEBT/RSB BE NRR/DLPG/HFB 10 NRR/DOEA/E*B 1 1 NRR/DREP/RPH 10 NUDOCS-ABSTRACT RES TELFORDr J RES/DRPB DEPY '1 " 1 '1 1 1 1 1 1 1 1 1 1 '1 1 1 1 2 2 1 1 1 1 1 1 EXTERNAL: EG'..G WILL IANSr 8 H ST LOBBY MARD NRC PDR NSIC NAYSr G 4 1 1 1 1 FORD BLDG HOY, A LPDR NSIC HARRISr J NOTES: 1 1 TOTAL NUMBER QF COP IES REQUIRED: LTTR 47 ENCL 46

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Page 1: auxiliary failed em'tt str ti - Nuclear Regulatory Commission · FACILITYNAME (I) DOCKET NUMBER 12) PA E 31 Palo Verde Unit 1 TITLE (4) Auxiliary Feedwater Pump Degradation o so oo

REGULF. <Y INFORNATION DISTR IBUTI SYSTEM ( R IDB )

DOCKET05000 2F

cBer

ACCEBBION NBR:8806080382 DOC. DATE: 88/06/03 NOTARIZED: N6F*CIL:STN-50-528 Palo Verde Nuclear Btationr Unit 1r Ar i zona Publi

AUTH. NANE AUTHOR AFF ILIATIONSHR I VER r T. D. Arizona Nuclear Power ProJect (formerly Arizona -PublicHAYNEBr J. G. Ar i zona Nuclear Power ProJect ( formerly Arizona Public

RECIP. NAME R EC I P I ENT AFF ILI*TION

SUBJECT: LER 88-013-00: on 880325r essential motor driven auxiliaryfeedwater pump failed to achieve rated pressurer per TechSpecs. Caused bg str ess corrosion cracking/hydrogenem'tt 1 ement. Nat 1 chang e s in it iat e d. 4l1880325 1tT .

DISTRIBUTION CODE: IE2 'D COPIEB RFCFIVED: LTR ENCL SIZE:TITLE: 50. 73 Licensee Event RepoT t (LER) r Incident Rptr etc.

NOTES." Stan dar d i z ed p lan t. 0 "000.," ..

REC IP IENT'ID

CODE/NANE'D5

L*LICITRArE

COP IESLTTR ENCL

1

1 1

'RECIPIENTID CODE/NAME

PD5 PD,DAVIBrN

COP I ESL'TTR ENCL"

1 1

1

INTERNAL: ACRB NICHELSONAEOD/DOAAEOD/DSP/ROABARN/DCTB/DABNRR/DEBT/ADB 7ENRR/DEBT/EBH SDNRR/DEBT/MEB 9HNRR/DEBT/PBH BDNRR/DEST/BGB BDNRR/DLPG/GAB 10NRR/DREP/RAB 10

/SIB 9A02

RES/DE/EIBRGN5 FILE 01

1 1

1 1

1 1

1 01 1

1

1 1

1

1

1

1

1

*1

ACRB NOELLERAEOD/DSP/NASAEOD/DSP/TPABDEDRONRR/DEBT/CEB SHNRR/DEBT/ ICBB 7NRR/DEST/NTB 9HNRR/DEBT/RSB BENRR/DLPG/HFB 10NRR/DOEA/E*B 1 1

NRR/DREP/RPH 10NUDOCS-ABSTRACTRES TELFORDr JRES/DRPB DEPY

'1 "1

'11 1

1

1 1

1 1

1 1'1 1

1 1

2 21 1

1 1

1 1

EXTERNAL: EG'..G WILLIANSr 8H ST LOBBY MARDNRC PDRNSIC NAYSr G

4

1 1

1 1

FORD BLDG HOY, ALPDRNSIC HARRISr J

NOTES: 1 1

TOTAL NUMBER QF COP IES REQUIRED: LTTR 47 ENCL 46

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I

Page 3: auxiliary failed em'tt str ti - Nuclear Regulatory Commission · FACILITYNAME (I) DOCKET NUMBER 12) PA E 31 Palo Verde Unit 1 TITLE (4) Auxiliary Feedwater Pump Degradation o so oo

NRC form 355(0031

LICENSEE EVENT REPORT {LER)

US. NUCLEAR REOVLATORY COMMISSION

APPROVED OMB NO. 31504104EXPIRES: 5/31/SS

FACILITYNAME (I) DOCKET NUMBER 12) PA E 31

Palo Verde Unit 1TITLE (4)

Auxiliary Feedwater Pump Degradation

o so oo 528>or 1 7

EVENT DATE(5) LER NUMBER (5) REPORT DATE (7) OTHER FACILITIES INVOLVED(I)MONTH DAY YEAR YEAR SEQUENTIAL

NUMBERREVISIONNUMBER MONTH DAY YEAR FACILITYNAMES

Palo Verde Unit 2

DOCKET NUMBERISIosooo52 9

0 325 88 88 0 1 3 0 0 0 6 0 3 8 8 Palo Verde Unit 3 o so o o 53 0OPERATINO

MODE 15)

POWERLEvEL

1 0 0

'f@((IECcN)5)~b'j-,'t

20A02(O)

20.405(el(1(B)

20.405 (o) (I ) (5)

20.405( ~ ) (I ) (rII)

20AOS(o) (1)(Iv)

20.405(o I II ) (v)

20A05(c)

50.3$ (cl(1)

50.35( ~ l(2)

50.73( ~ I(2III)

IN.13(e)(2 I IN)

50.73(o) (2)(BI)

LICENSEE CONTACT FOR THIS LER O2)

50.73( ~)(2)(wl

50.73(o l(2)(v)

50.73(o)(2) (r)ll

50,73( ~ l(2)(rIII)IAI

50.73(o) (2)(vIEI(5)

50.73(o)12)(o I

THIS REPORT IS SUBMII'TED PURSUANT TO THE REOUIREMENTS Of 10 CFR (II ICnec4 one or more o/ tne Ioiiowinp/ (11

73.71 (II)

73.71(cl

OTHER ISpeCIIy in AprtriiIOelow end in Tent, IIIICform3FPA/

10CFR21.

NAME

Timoth D. Shriver, Compliance Manager

TE(.EPHONE NUMBER

AREA CODE

602393-2521COMPLETE ONE LINE FOR EACH COMPONENT FAILURE DESCRIBED IN THIS REPORT (13)

CAUSE SYSTEM COMPONENT NUTURER ""'"," QRAW%%@SPÃi'.

y ".. rower «O'OC/'-'.

CAUSE SYSTEM COMPONENT MANUfACTVRER

EPORTABLETO NPRDS (~ >%M@~ '%jF'4 '"'

B A PB 26 0 Y

..'SXNI.r gekg-"igrng"

SUPPLEMENTAL REPORT EXPECTED ()4) MONTH DAY YEAR

YES IIIyet, compiete EXPECTED St/SM/SS/0/Y DATE/ NO

'XPECTEDSU 5 MISS ION

DATE (15)

ABSTRACT I(,imit to te00 tpecet, it., epprocimMeiy fr/teen tinpie /poco typewritten /inn/ (15)

On t/larch 25, 1988 Palo Verde was in Mode 1 (POWER OPERATION) at approximately100% power when the essential motor driven auxiliary feedwater pump did notachieve its rated pressure in accordance with PVNGS Technical Specifications.An engineering evaluation completed on June 1,,1988 determined the .root causeto be stress corrosion cracking/hydrogen embrittlement of the shaft sleevewhich permitted the sleeve to move and eventually wear the fourth stageimpeller to the point that it was permitted to rotate freely about the shaft.A similar event was identified involving the Unit 1 non-essential auxiliaryfeedwater pump on June 1, 1987.

As corrective action, material changes will be incorporated into the auxiliaryfeedwater pumps for Units 1, 2 and 3.

'-. This. report -is also being submitted pursuant to .10CFR21..

8806080382 880603PDR *DOCK 05000528S PDR

NRC form 344

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Page 5: auxiliary failed em'tt str ti - Nuclear Regulatory Commission · FACILITYNAME (I) DOCKET NUMBER 12) PA E 31 Palo Verde Unit 1 TITLE (4) Auxiliary Feedwater Pump Degradation o so oo

NRC Porm 344AI983 I

LICENSEE EVENT REPORT {LER) TEXT CONTINUATIONU 4 NUCLEAR REGULATORY COMMISSION

APPROVEO OMS NO 3(50-GIG4EXPIRES: 8r3l/48

PACILI'TY NAME (ll

Palo Verde Unit 1

TEXT IIP mrrrP a»cP r8 m4uked, rr» PIOPrrPPHRC Form 384A3 I (Ill

DOCKET NUMSER (11

p s p p p 5 2 8 8 8

LER NUMEER (4)

~i(' 4 Qv 4 NT I AL s+yR rrsv rs rorrNUMSSA»'rUMSSA

01 3 00

~AGE ISI

0 2oF ] 7

This report is also being provided pursuant to the provisions of 10CFR21. Thenarrative below includes the information requested by 10CFR21.21 (b)(3);however, it is being formatted to report this event in accordance with therequirements of 10CFR50.73.

I. DESCRIPTION OF WHAT,OCCURRED:

A. Initial Conditions:

B.

At the time of the first auxiliary feedwater (AFW) pump (BA)(P),degradation on June 1, 1987 at approximately 1735 MST, Palo VerdeUnit 1 was.in Mode 1 (POWER OPERATIONS) at approximately 40 percentpower.

At the time of the second AFW pump degradation on March 25, 1988 atapproximately 0324 HST, Palo Verde Unit 1 was in Mode 1 atapproximately 100 percent power.

Reportable Event Description (Including Dates and Approximate Timesof Major Occurrences):

Event Classification: Condition which caused two independent trainsto become inoperable in a single system on different occasions.

Note: This section includes information requested by 10CFR21concerning the nature of the .defect and dates for which..informationwas obtained/developed.

On June 1, 1988 an engineering evaluation was completed concerningthe auxiliary feedwater pump problems described herein. Based uponthis review, it was determined that the similar failure mechanismresulted in the condition being reportable pursuant to 10CFR50.73 and10CFR21.

Palo Verde Unit 1 has experienced two similar occurrences whichresulted in auxiliary feedwater (AFW) pump degradation. The mostrecent occurred on March 25, 1988. During the performance of amonthly surveillance test on the "B" Train essential motor-driven AFW

pump, it was observed that the total delivered head was below theallowable value of 1682.2 hasid; The actual total delivered head was1'538;5 psid. This value was approximately 210 psid below the 'valueof 1748 psid which was obtained in the previous surveillance test forthis pump. The pump was declared inoperable and disassembly wasinitiated. The following observations were made during the visualinspection of the pump's rotating assembly: First, the fourth stageimpeller hub was observed to be capable of rotating freely around thestationary pump shaft. 'There was also evidence of grinding on the.center stage piece side of the fourth stage impeller hub. -Secondly,the center stage shaft sleeve was also free to rotate .about the pump

vAC r(IRM ESSAI9 83r

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II

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NRC form 84%A19 831

0LICENSEE EVENT REPORT {LER) TEXT CONTINUATION

U.S. NUCLEAR REGULA'TORY COMMITS/ON

APPROVED OMS NO 8150 0104EXPIRES) 8/81/88

fACILITYNAME (ll DOCKET NUMSER IEI LER NUMSER ISI

YEAR IIorN SEGVENT/ALNVM IA

Asv/sloNNVMOSA

Pal o Verde Uni t 1

TEXT ///moro sooso is oor/rirorE rros asskoono/HiIC form SR''s/(ITI

o s o o o 5 2 8 8 8 —0 1 3 0 0 0 3 oF1 7

shaft. By design, the center stage shaft sleeve is shrink fittedonto the shaft and also keyed to the shaft. Visual observationshowed a crack ~n The outside surface of the center stage shaftsleeve that went axially along the entire length of the shaft sleeveat the keyway location.

The previous instance of AFW pump degradation of this type occurredon June 1, .1987. This event affected the non-seismic, non-essential,motor-driven AFW pump. The visual inspection of the rotatingassembly for this pump yielded many of the same observations thatwere described .above. Specifically, the center shaft sleeve had an*

axial crack, the key had been sheared, and the sleeve was free torotate about the shaft. The key had also been sheared at the fourthstage impeller hub allowing freedom of rotation of the fourth stageimpeller hub about the shaft. The rotating assembly for the pump wasreplaced.

C.. Status of structures, or components that were inoperable at the startof the event that contributed to the event:

Other than the AFW pumps, there were no structures, systems, orcomponents inoperable which contributed to the event.

.D. .Cause .of..each component or .system failure, if known:

Note: This section includes information requested by 10CFR21concerning the nature of the defect and dates for which informationwas obtained/developed.

As a result of the first failure on June 1, 1987, ANPP contacted theoriginal equipment manufacturer (Bingham-Willamette) and the damagedrotating assembly was sent to them for their evaluation and repair.The conclusion from the vendor's initial evaluation was that thedamage was due to water hammer or excessive pulsations at thedischarge side of the pump. Bingham-Willamette (BW) has sincerevised this root cause based on the second failure.

Following the second failure, ANPP initiated an extensiveinvestigation to determine the extent of the problems describedherein. ANPP initiated a search within the industry to determine if

. any other plants with similar BW pumps had experienced problems of- this type. The vendor was contacted and asked if they knew of anyproblems of this type that had been experienced by other users oftheir pumps. The vendor replied that they were unaware of any otherfailures of this type. Further investigation by ANPP revealed thatSouth Texas Project (STP) Unit 1 had recently experienced a failureof one of their AFW pumps. Some .of the damage reported by STP issimilar to the damage experienced by the Palo Verde pumps. ANPP alsoconducted a Nuclear .Plant Reliability Data System (NPRDS) search to

NAC r /IAM fooo19 SI I

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N RC F orm 3$ 9A1993)

LICENSEE EVENT REPORT (LER) TEXT CONTINUATIONU.E. NUCLEAR RECULATORY COMMIEErON

APPROVEO OMS NO 3150&104EXPIRES'I31/89

FACILITY-NAME I1l

Palo Verde Unit 1

TEXT IJT more u»ce lI eerrkerE rree~ HRC Form 30EA'Fl 1171

OOCKET NUMSER I31

o s o o o 5 2 8 8 8

LER NUMEER IEI

SEOVENTIALNVM ER

0 1 3

rrEVlSIONNUMFER

0 0

~AGE 131

040F 1 7

determine if this failure mechanism had been experienced previouslyat other utilities. There were no NPRDS reports of similar failuresat other operating 1Iti]indies.

ANPP conducted a multi-disciplinary review of the AFW pump problems.The review involved different groups within ANPP as well as outsideorganizations. The Hechanical Group of ANPP's EngineeringEvaluations Department (EED) took the lead in the investigativeefforts which were aimed at determining a root cause of the AFW pumpdegradations. The Technical Support group of EED was involved toprovide metallurgical analysis support, and they .contracted with. anindependent laboratory, HETL, to perform the actual metallurgicaltesting of the center stage shaft sleeve. ANPP's EngineeringDepartment Hechanical Group and Reliability Group provided technicalsupport and,probabilistic analysis to support the effort. ANPP'sNuclear Fuel Hanagement (NFH) Department was contacted to determinethe impact of reduced AFW pump flows .on the accident analyses. NFHalso consulted with Combustion Engineering for their evaluation.ANPP obtained technical support from Bechtel Power Corporation (BPC)and the pump manufacturer (Bingham-Willamette) to aid in theevaluation of the AFW pump degradations. BPC then involved anindependent pump consultant and BPC's Haterials and guality Services(HagS) group. The pump manufacturer contracted with an independentlaboratory, Oregon State University (OSU), to perform a metallurgicalexamination of the center stage'haft sleeve.

As a result of ANPP's root cause investigation, the following failurescenario was developed. The initiating event was a crack in thecenter stage shaft sleeve. The existence of the crack allowed theshaft sleeve to expand which eventually resulted in the shearing ofthe key due to the frictional forces between the sleeve and thecenter stage piece. The shearing of the key gave rotational freedomto the shaft sleeve. The differential pressure that is normallydeveloped across the shaft sleeve is approximately 800 psid due tothe pressure differential between eighth stage and fourth stagepressures. This pressure differential forced the center stage'haftsleeve into the fourth stage impeller hub. The shaft sleeve groundinto the impeller'ub removing hub and key material. Finally, thesleeve reduced the key in the impeller to such a dimension that theimpeller torque sheared the remaining length of the key. The fourthstage impeller was then free from the rotation of the shaft and thedeveloped head of the pump was reduced.

The following information is provided concerning the originalequipment manufacturer's evaluation of the Palo Verde experience. OnApril 4, 1988, Bingham-Willamette (BW) met with ANPP personnel todiscuss the problems found while disassembling the JJni.t 3 B-Train AFW

pump. BW reviewed the video taken of--the damaged rotating assembly.Discussions were also held concerning the condition of the Unit l

41C IOAM 34eo19 Slr

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l

k

t

Page 11: auxiliary failed em'tt str ti - Nuclear Regulatory Commission · FACILITYNAME (I) DOCKET NUMBER 12) PA E 31 Palo Verde Unit 1 TITLE (4) Auxiliary Feedwater Pump Degradation o so oo

0NRC Fo(m 3SSA(983(

LICENSEE EVENT REPORT ILER) TEXT CONTINUATIONV 8 NUCLEAR REOVLATORY COMM(SSION

APPROVEO OM8 NO 3(SP p(psEXP(RES; 8/31/88

FACILITYNAME II > OOCKET NVMSER (3l LER NUMSER (8)

S 8 QV8 NTIALNUM KR

REVISIONNVM f4

PAOE (3(

Palo Verde Uni t 1

TEXT ////sss/P SPscs il/PSMPINL vss ~/YRC FP/111 3(SEA's/ (ITI

o s o o o 52 88 8 013 —0 0 0 5 OF 1 7

non-essential AFW pump rotating assembly from the failure of June, . *

1987. BW stated that the damage to the two rotating assemblies isvery similar SW ~as .given hal.f af the ~enter stage shaft sleeve fora failure analysis. BW then witnessed the starting of the Unit 1

essential AFW pump which had been instrumented on the suction side ofthe pump with pressure gauges. During the start of the B-Train AFWpump, swings from 0 to 60 psi for 3-5 seconds were observed on thesuction side pressure gauge until the pump steadied out. After therun, BW performed a walkdown of the suction piping for the AFW pump.One of the BW representatives noted that there was nothing unusual .about the PVNGS suction piping arrangement that would lead .them to

'elievethat this is a problem for mini-flow pump starts.- They werethen taken to Unit 2 to inspect the non-essential AFW pump which hadbeen disassembled for inspection as a result of the problemdiscovered in Unit 1. The center stage shaft sleeve for the pump wasnoted to have moderate rotational marks, but no bluish tempering wasfound. The sleeve was in its design position, and no visual signs ofany differential rotational movement between the shaft sleeve and thefourth stage impeller hub were found. The lower center stage piecerevealed light to moderate signs of rubbing contact. The upper halfshowed very light signs of contact.

The observations. made by BW during their trip to Palo Verde and thesubsequent review of the essential AFW. pump damage at their facilityhave lead them to believe that the pumps were exposed.to severeoperating. conditions. Specifically, BW postulates that the pumpshave 'either been subjected to dry starts (loss of suction pressure)or starts under conditions wherein the auxiliary feedwater flow isaligned for steady state flows at or near the design flow (1010 GPH)of the pump. To shear the key, a. considerable torque must act on thesleeve. BW performed an analysis to estimate the maximum frictionalforces which can occur during pump upsets. Particularly, the case ofpumping a two phase fluid (water/vapor) was considered. A simplifiedmodel was used in which it was assumed that, in the worst case, 4 ofthe 8 impellers would be half filled with water and the remainderwith vapor. The results are:

i), With a friction factor of 0.3 (dry steel against steel), the*

torque developed by this upset is only about 10% of the torquenecessary to shear the

key.'i)

To shear the key the sleeve must at least temporarily gall. Ifthis happens, the necessary torque is about 4 times larger thanis needed to shear the key. The fact that the center stagepiece does not rotate, although held by a relatively small pinonly, indicates that the shearing of the key happens rapidly

„.wi.th -not enough time to accelerate the heavy -center stagepiece. This would support the argument that at least temporarysudden galling of the sleeve is necessary for shearing the key.

NNC lOAM SSSS(9 831

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NRC Form 344A19 831

LICENSEE EVENT REPORT (LER) TEXT CONTINUATIONU.S. NUCLEAR REOULATORY COMMISSION

APPROVEO OM8 NO 3150-0104EXPIRES! 8/31/88

FACILITYNAME 111 OOCKET NUMSER I3> LER NUMSER 181 ~AOE 131

Palo Verde Unit 1

TEXT ///rrroro sooco is roorrinssE I/so /orssonrs/HITC Fo/rrr 3/SSA'4/1171

o s o o o 5 2 8

VEAR 15+;

8 8

SEQUENTIALNVM SA

013II4 v IS IONNUM 4 II

00 06 QF1 7

BW indicated that galling marks on the center stage piece and centersleeve are strong evidence that dry starts or starts with subsequenttwo phase flow have occurred for the failed pumps. Each ef Thesephenomena are discussed below:

i) Normal Starts. BW estimates that the motor-driven pump startsin less than once second. The inertia of the .water in the longsuction line (approximately 200 feet) prevents the water frommoving into the eye of the first stage impeller at the samerate as the pump is removing water from the case.Consequently, the pressure at the suction nozzle of the pumpdrops below the vapor pressure -of the water in the suctionline. This results in two phase flow through the pump. Thetwo phase flow can lead to one of the following two occurrencesor a combination of both. First, the impeller(s) can contain amixture of vapor and water which is not evenly distributedthroughout the impeller. This imbalance condition causes theshaft to move erratically with the largest shaft deflectionstaking place at the center stage sleeve. The sleevecontacts/rubs the center stage piece leading to the observedgalling. Secondly, two phase conditions inside the pump couldexist over a large portion of the pump which reduces thehydrodynamic lift effects on the sleeve. The reduction inhydrodynamic lift leads to the sleeve contacting the centerstage piece which results in the galling of both pump parts.

Compounding the above effects of two 'phase pump operation, thewater column which separates at the pump suction nozzle willrejoin when the water in the suction line starts to move. Therejoining results in a water hammer, pla'cing an additional loadon the shaft which may be. in a deflected state or. movingerratically, thus causing or amplifying the radial forces whichare necessary to deflect the sleeve enough to contact/rub thecenter stage piece.,

Dry Starts. BW postulates that the suction valves may havebeen closed when the pump was inadvertently started (Based uponANPP's investigation into this event, it could not beestablished that this has occurred at Palo Verde.). This wouldlead to the loss of the hydrodynamic lift effect at the centersleeve. Heavy rubbing on the lower half of the center stage-piece would occur with subsequent gal,ling of the parts.

4AC I 0AM '1444IS 83r

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NRC Foam 344AI9 93 I

LICENSEE EVENT REPORT ILER) TEXT CONTINUATIONU S NUCLEAR REOULATORY COMMISSION

APPROVEO OMS NO 3150 OIS4EXPIRES.'d/31ISS

FACILITYNAME III DOCKET NUMSER l?lLER NUMSER ISI PAGE LTI

Palo Verde Unit 1

TEXT N ANv4 SP444 ir mdviraE vFF SddeonMF HRC form 3RLS'4 I (ITI

o 5 o o o 5 2 8

YEAR gg

8 8—SEOVSNTIAL

NVM SR

0 1 3—~IEVIS KINMVMPS R

0 0 07 OF 1 7

An independent pump consultant was retained by Bechtel PowerCorporation (BPC) to perform an evaluation of the AFW pump degradationproblems at PVNGS. This .paragraph summarizes The mnsul&nt'~findings. The consultant performed an inspection of the damagedrotating assembly of the essential motor-driven AFW pump before theassembly was shipped .to BW. His evaluation corroborated the failurescenarios developed by ANPP. Specifically, he stated that the end toend split of the shaft sleeve initiated the failure. Once the crackwas fully developed, the sleeve would expand to allow contact with thebushing. The resultant torque sheared off the key, and the* sleeve,under eighth, stage pressure, began drilling into the fourth .,stageimpeller hub. .After enough metal was removed from the impeller hub and'haft key, the torque sheared the shaft key which freed the impellerfrom positive drive. Another interesting finding from this pumpconsultant is that there is no reason to suspect that furthermechanical problems would occur following the loss of the fourth stageimpeller that would prevent continued use of the pump at a reducedflowrate. The consultant also expressed concerns -regarding the shaftsleeve design. In particular, he was concerned by the thickness of theshaft sleeve, the hardness of the material, and the stressconcentrations created by the 0. 125 inch deep keyway in the 0.250 inchthick sleeve material. As a result of his concerns, the consultantrecommended that the thickness of the center. stage shaft sleeve bedoubled .and that the material be replaced with a material that is notas hard as that 'currently used. --This recommendation has been evaluatedand ANPP considers that this is not practical due to the increase inaxial loads on the sleeve that would result from the change.

An ANPP metallurgical analysis of the cracked shaft sleeve hasconcluded that the cracking is due to hydrogen embrittlement cracking.This determination is based upon an investigation, which includesScanning Electron Microscopy (SEM) showing intergranular cracking, anaverage material hardness of Rockwell C-50, and applied radial forceson the shaft sleeve. The susceptibility of martensitic stainlesssteels with high hardnesses to hydrogen embrittlement is welldocumented and supports ANPP's conclusion. There was no evidence tosuggest the ductile overload or fatigue modes of cracking. Secondaryheat induced -cracks were also identified on the shaft sleeve insidediameter, however, these cracks were a result of severe galling andintense localized heating. Bechtel has examined the failed shaftsleeves at a Palo Verde and STP. The examination of. the Palo Verdesleeve confirms the metallurgical examination results of stresscorrosion cracking/hydrogen embrittlement performed by ANPP.Additionally, Bechtel has found significant similarities between thePalo Verde and STP sleeve failures that suggest that the fracture modesare the same. These similarities are summarized below:

4AC TVAM 3944I9 93<

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NRC Fosm SSSAI9.83 I

LICENSEE EVENT REPORT ILER) TEXT CONTINUATIONU.S. NUCLEAR REOVLATORY COMMISSION

AFFROYEO OM8 NO 3180 010SEXFIRES. SI31188

FACILITYNAME OI

Palo Verde Unit 1

TExT IifmosF FFscf ie ssfswed, sssf A3sf8svs FIRc Foms %54'sl II3 I

OOCKET NVMSESI IS)

o 5 o o o 52 88 8

LER NVMSER (8)

SSQVS NfiAL P~ ASVsfiVssSSVSS fA 'i VVMFfA

01 3 00 08 OF 1 7

i) The material is Type 420 stainless steel, which was hardened toa high hardness level (50/51 HRC). Steels, including chromiumstainless steels, in' high hardness -condition (higher than 88HRC) are-known to be susceptible to stress corrosioncracking/hydrogen embrittlement.

ii) The- fracture occurred in or around the keyway corners where thestress (residual tensile stress in the circumferentialdirection from heat treating and shrink fit) would be thehighest.

iii) The fractures initiated at the -keyway surface, rather than atthe outside surface of the sleeves.

iv) The sleeves show evidence of corrosion in the areas of fractureinitiations.

v) The fracture faces of the splits are intergranular.

ANPP conducted a review of the operating history of the AFW pumps ineach unit. One of the factors that was investigated was how many fullflow pump starts the essential AFW pump had experienced in each unit.

, The results of the review indicate that the Unit 1 pump had .experiencedan estimated 27 full flow pump starts, the Unit 2 pump had.3, and theUnit 3 pump only had 2 full flow starts. The reason the Unit 1

essential AFW pump has experienced more full flow starts is attributedto additional preoperati'onal testing that was conducted only in thelead unit. Based upon a BW hypothesis concerning galling during fullflow pump starts and the operating, history data, ANPP expects that moregalling would have occurred in Unit 1 than Units 2 and 3. This hasbeen partially confirmed by the inspections conducted on the essentialAFW pumps in Units 1 and 2. The cracked shaft sleeve for the Unit 1

pump had indications of severe galling while no signs of galling werepresent on the Unit 2 pump's shaft sleeve. As an additional note, fullflow starts of the steam turbine driven and non-essential AFW pumps arenot a concern for this investigation due to design and proceduralconsiderations which preclude full flow starts of these pumps.Additional operating information has been gathered to aid in thereliability analyses that ANPP has performed. The demand and run timesassociated with the Units 1, 2, and 3 AFW pumps are summarized in thefollowing table.

'iSl C I IISs M Sf 9 A

I9 83>

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'I

i

I

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NRC Form 344Al8$3l

LICENSEE EVENT REPORT (LER) TEXT CONTINUATIONU.S. NUCLEAR REOULATORY COMMISSION

APPROVED OMS NO 3150&I04EXPIRESI SI31l88

FACILITYNAME Ill DOCKET NUMSER Ill LER NUMSER (8)

yEAR E@P SEovsNTIAL I';rlNVM SR

REVISIONNVMSSR

~AOE ISI

Palo Verde Unit 1

TEXT N mam Smmmu II rmumlmd. vmu~ HIIC Funm 3834 Sl I'lllp p p p p 5 2 8 8 8 0 1 3 0 0 0 9

1 7

AFW PUMP RUN TIME STARTS

Unit 1 DE

H'teamTurbineDrivenEssential~Pum

200331

Motor DrivenEssentialBeforeFailure

249(2)606(2)

Non-Essential~um

1473643

5on-EssentialPumpAfter~Fi1

63959

Unit,2 DE (3)HE (3)

123200

109330

1431960

Unit 3 D'3)HE (3)

3180

124390

27560

TOTAL D'3)HE (3)

354611

4821326

3176163

63959

DE = Start/Stop CyclesH' Run Time (Hours)

Notes:

E.

(1) Includes starts and run hours that this pump experienced in Unit3 prior to being. moved to Unit 1 in June, 1987 .

(2) Unit 1 essential, motor-driven AFW pump failed on3/25/88.'3)

Estimated values in Units 2 and 3 during operational phase.

Failure mode, mechanism, and effect of each failed component, ifknown:

See Section D above.

F

G.

-For failures of components with multiple functions, list of systemsor secondary functions that were also affected:

Not applicable - Other than feedwater flow during differentoperational conditions, the AFW pumps do not have multiple functions.

For failure that rendered a train of a safety system inoperable,estimated elapsed time from the discovery of the failure until thetrain was returned to service:

4RC IDRM 344AIS 83I

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t

t

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NRC Sorm 3OSA19431

LICENSEE EVENT REPORT <LER) TEXT CONTINUATIONU.S. NUCLEAR REGULATORY COMM/33/PN

APPROVEO OMS NO 3/EQUIPSEXPIRES: S/31/SS

SACILITYNAME 111 OOCKET NUMSER LTI LER NUMSER LSI

YEAR Krree SEPUENTIAI r K +EVISIPII~IUM TA Or I/UMoe/I

PAGE 13)

Palo Verde Uni t 1

TEXT //Smote soese ie ee/rirN/. Use ///o'oos/H/IC Som/3/E/A'/llllo so oo 528 8 8 01 3 00 1 0 oF 1 7

The non-essential AFW pump was discovered to be inoperable atapproximately 1735 HST on June 1, 1987. The pump was repaired andreturned to service at approximate]y l627 HST on June 4, l987. Thepump was inoperable approximately 70 hours and 52 minutes.

The essential AFW pump was discovered to be inoperable at'pproximately0324 HST on Harch 25, 1988. The pump was repaired and

returned to service at approximately 0917 HST on Harch 27; 1988. Thepump was inoperable for approximately 53 hours and 53 minutes.

-H. .Hethod of discovery of each component or system failure or proceduralerror:

The problems with the AFW pumps not producing the required head werediscovered during the performance of routine surveillance testing.The failed shaft sleeves were discovered as a result of maintenanceand engineering investigation into the reason for the AFW pump notmeeting the appropriate surveillance acceptance criteria requirements.

I. Cause of Event:

This section includes information requested by 10CFR21 concerning thenature of the defect.

— Two separate root .causes have been identified for the failurescenarios discussed previously. Before these root causes arediscussed, it should be noted that all parties involved in theinvestigation are in agreement on the end portion of the failurescenario. Specifically, the different groups looking into this eventagree that galling between the center stage shaft sleeve and thecenter stage piece must exist in order to generate high enough forcesto shear the shaft key. After the shaft key shears, the shaft sleeveis free to rotate which leads to machining of the fourth stageimpeller hub. The fourth stage impeller hub eventually breaks freefrom the shaft. Two failure mechanisms have been developed toexplain how and why the galling of the shaft sleeve occurs. Thesetwo failure mechanisms are presented below.

i) Suction Transients

The galling of the center stage shaft sleeve to the center stagepiece could occur as a result of suction transients on the AFW

pumps. Suction transients can be caused by either plantoperation or plant design. Normal starting of .the motor-drivenAFW pumps can lead to a condition where the pressure at the

. suction nozzle of the pump drops below the vapor pressure of thewater in the eduction line. His is .due to -the inertia .of thewater in the suction line which prevents the water from movinginto the eye of the first stage impeller at the same rate that

vAC IPRII 3ees19 STI

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tI

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NRC Form 384AI943I

LICENSEE EVENT REPORT'(LER) TEXT CONTINUATIONU S. NUCLEAR REOULATORY COMMISSION

APPROVEO OMS NO 3150WIOEEXPIRES: 8r31/88

FACILITYNAME III

Palo Verde Unit 1

TEXT Iiimart ssrtst is ssrr'rtrE rrss ~HiICfamr 388A'sl Ill)

OOCKET NUMEER (ll

o s o o o 52 88 8

LER NUMEER LSI

..'rSR $ EovENTIAL pr<. REvlsloNNUM 8 E R ~ '8

~ N VMS E R

0 1 3 0 0 OF 1 7

the pump is removing water from the case. This condition cariresult in galling of the center stage sleeve, by either causingan imbalance of the pump shaft or by reducing the hydrodynamiclift effect at the sleeve location. Another plant operatingproblem that can lead to galling occurs if the non-essentialAfW pump is started with at least one of its two motoroperated suction isolation valves Hosed (It could not beestablished that this situation has occurred at Palo Verde).Again, this leads to an inadequate suction water supply forthe pump which could lead to galling of the shaft sleeve dueto loss oF the hydrodynamic lift effect at the center stageshaft sleeve.'ne possible plant design problem that couldlead to galling is long horizontal runs of suction pipingimpacting pump startup. If the piping is not adequatelyvented following system maintenance, then air could beingested at the pump suction again leading to galling of thecenter stage shaft sleeve.

Environmental Crackin

The galling of the center stage shaft sleeve could have beeninitiated by the observed axial crack in the shaft sleeve.Specifically, the crack in the >haft sleeve was initiated byintergranular attack. = When the crack had.fully propagated, itreduced the diametral clearance between the'enter stage pieceand the shaft sleeve. This led to inadequate cooling flow tothe shaft sleeve which resulted in galling.

ANPP analysis indicates that the root cause of failure is due toenvironmental cracking or a combination of environmental cracking andsuction transients. from the evidence cited below, ANPP concludesthat the dominant failure mechanism is environmental cracking andthat sleeve cracking is a prerequisite condition for suctiontransients to contribute to pump failures.

i) Primary Root Cause (environmental cracking).

'. Hetallurgical analysis has indicated that the chief mode ofcracking on the Palo Verde center stage shaft sleeves isintergranular crackirig due to hydrogen embrittlement. The

, above conclusion is supported by fractographic examinationalong the fractured face of the failed sleeve. The micro

'ardnessmeasurements indicate that, during the earlysequence of the event, the sleeve had rubbed or galledagainst the center stage piece. Therefore, it can beconcluded that the sleeve had expanded sufficiently toreduce and/or possibly e]iminate drooling/jobe water„ whichwould result in an upset condition causing the key .to .shear.

NRC EORM SEERIS Slr

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NRC POIIII 344Af9II3I

LICENSEE EVENT REPORT {LER) TEXT CONTINUATIONV.S. NUCLEAR REOULATORY COMMISSION

APPROVEO OM8 HO 3150 0104EXPIRES: 8I31I88

PACILITYNAME 11) OOCKET NUMSER ETI

YEAR

LER NVMSER l4lSEOUEHTIAL 1«4 IIEVISION

~4UM %A «+I HUMPTA

PACE LTI

Palo Verde Unit 1

TEXT II/III4«4 aOe44 N nqcWed. IIWeANxnef HIIC FOen 38SA 3l IITI

o s o o o 5 2 8 8 8 01 3 —00 12oF1 7

'uring the April, 1988 inspection of the Unit 2non-essential motor-driven pump, BW indicated that the lowerhalf of the center stage piece showed signs of heavyrubb'ing. BM believes that this is an- indication that drystarts have occurred (ANPP could not establish that this hasoccurred at Palo Verde.). Further investigation byNondestructive Examination (NDE) revealed that both thecenter stage and throttle sleeves did not have any ID or.OD,cracks.

'leeve cracking existed for the .two observed Palo Verde pumpfailures.

Secondary Root Cause (environmental cracking/suctiontransients).

'leeve cracking and suction transients do not existsimultaneously for the Palo Verde Unit 2 pumps that havebeen inspected.

'uring the BW trip to Palo Verde in April of 1988, a normalstart (estimated to be one second or less) of the essentialAFW -pump was .performed. ,The suction line was. fitted with acompound -(vacuum/pressure) gauge and the pump was alignedfor mini-flow operation. In this configuration, thepressure at the pump suction pegged the pressure gauge toless than zero. - Based on BW's observations and subsequentanalysis of the pump start during minimum flow operation, BW

indicated that starts with the pump aligned for flows at ornear the design flow would, degrade suction pressure to theextent that the pump would operate under two phaseconditions.

'nterviews with ANPP personnel have indicated that theessential motor-driven AFW pump in Unit 1 had lost suctionflow at least once over the operating history of the pump.During the performance of a startup procedure on July 15,1984, the pump's suction was transferred from the CondensateStorage Tank (CST)(KA) to the Reactor Hakeup Mater Tank(RNWT)(CB). During-the transfer sequence, the pumpdischarge pressure dropped and the test was discontinued.'.subsequent investigation revealed that the suction line fromthe RNWT was not vented and the pump had become air/vaporlocked with the resulting loss. of dischar'ge pressure. Tocomplete the test, the suction line from the RHWT wasvented, the pump was restarted and proper discharge pressureestab] ished when testiag continued. The .pump was notinspected prior to the continuation of testing.

'IIIC IIIIIM3444l9 83 ~

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NRC F»» ESSA(BSISI

LICENSEE EVENT REPORT ILERI TEXT CONTINUATIONU.d. NUCLEAR REGULATORY COMMISSION

APPROVEO OMB NO B(50&((NEXP(RES; d/O'I/dd

FACILITYNAME (II

Palo Verde Unit 1

TExT /// /ss///p spsss is sdsss'sE s/» a Assens//Y/IC fess// JR(A'/ I(T)

OOCKET NUMBER (TI

o s o o-o 5 28 88

LER NUMBER (SI

Nr<g SEQVENT/*L4 «s/VMS ~ R

0 1 3

Frr, A(v/SIQ/sE~R s/VMSSR

—0 0 13OF1 7

'leeve cracking and suction transients existed for one ofthe observed PVNGS pump failures.

'.BW'.s experience has shown that a shaft sleeve crack byitself is not always a sufficient condition for pumpfailures.

In summary, ANPP has determined that the root cause is materialselection for the center stage shaft sleeve. The sleeve crackingalone can result in galling of the center stage shaft sleeve. It hasbeen determined that suction transients can contribute to thegalling; however, sleeve cracking is required as a precursor event.

Safety System Response:

There were no safety system responses and none were necessary.

K. Fail ed Component Information:

Note: This section includes information reqeusted by 10CFR21concering the identification of the firm supplying the basiccomponent and the number and location of the AFW pumps at Palo

- Verde. Additional information .concerning the number and location of-similar AFW pumps .supplied to other facilities should be obtainedfrom the manufacturer.

There are three Auxiliary Feedwater (AFW) pumps for each Palo Verdeunit. The AFW system for each PVNGS unit consists of one SeismicCategory I motor-driven pump, one Seismic Category I steamturbine-driven pump, and one non-seismic motor-driven pump.

The nine AFW pumps at PVNGS were manufactured by Bingham Willamette(BW) of Portland, Oregon. The pumps are BW Model 4x6xIO-I/2 B HSTeight stage units. Each essential AFW pump has a rated capacity of1010 gpm at 3280 feet Total Dynamic Head (TDH); The non-essentialAFW pump has a rated capacity of 1010 gpm at 2960 feet TDH. Thepumps are eight stage, single suction, double volute with ahorizontal split casing.- The rotating element is supported with

. sleeve journal bearings'at both ends outboard of the stuffing box andthe pump has 'an oil-lubricated -ball thrust bearing assembly locatedopposite of the driver end. The configuration of the impellers onthe pump shaft is commonly called the opposed impeller arrangement.The purpose of this arrangement is to reduce axial thrust loading.In this arrangement, the first four impellers are arranged on thepump shaft facing in one direction with the remaining four impellersfacing in the opposite direction. This design requires an interstagebushing -assembly -to separate the apposed -impel-lers at -the -pump centerbetween impellers four and eight.

'sAC s 0AM SSSAIS BSs

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t

It

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NRC form 388A/983/

LICENSEE EVENT REPORT (LER) TEXT CONTINUATIONU 8 NUCLEAR AEOUSA'TO/ly COMM/SS/ON

APPROVED OMB NO 3150-0104EXPIRES: 8/31/88

DOCKET NUMBER (3/ EER NUMBER (8)

yEAR gag'EOUBNTIACNI/M 8 N

AEVISIONNUMOSA

Palo Verde Unit 1

TEXT /// moso sooco /I IPOMPec/, oso AS/osmo/ i///C %%d/III 3//SA's/ I17>

o 5 o o o 5 2 8 8 8 0 1 3 00 14 0F 1 7

The interstage bushing (center stage shaft sleeve) is approximately 3inches long and 0.25 inches thick. It is manufactured from AISI 420material, hardened to Rockwell C-50.5 hardness. The sleeve isshrunk-fit to the shaft, to form' small interference fit of 2 mils orless. The sleeve is also keyed to the shaft by a key that is commonwith fourth stage impeller. The sleeve is surrounded by a stagepiece forming a hydrodynamic bearing. There is a groove within thecenter stage piece that'spirals around the center stage sleeve forpumped fluid flow. While the pump is at rest, the center shaftsleeve is resting on the center stage piece. Upon startup, therotating shaft is then supported by a film of pumped fluid that is ,for'ced through the annulus region between the center stage piece andthe sleeve by the pressure differential between -the eighth and fourthstages. Thus, upon startup, there is usually contact between thecenter stage shaft sleeve and the center stage piece.

II. ASSESSMENT OF THE SAFETY CONSE(UENCES AND IMPLICATIONS OF THIS EVENT:

Note: This section contains the information requested by IOCFR21concerning the nature of the safety hazard which is created or could becreated.

'ANPP .performed an evaluation of the affect of the degraded AFW pump-performance on the, relevant accident analyses. ANPP first determined theimpact of a loss of the pump's fourth stage on the amount of flowdelivered to the steam generators. Information was also obtained from BW

as to the impact on the pump's'lowrate for the loss of the fourth stageimpeller. The ANPP analysis indicates that one AFW pump will deliver 559gpm to the steam generators following the loss of the fourth stageimpeller. This is compared to the 750 gpm which is assumed in thecurrent accident analyses. It should be noted that the degraded AFW

pump will still be capable of delivering this reduced flow to the steamgenerators under all conceivable operating pressures (i.e., up to thelift setting of the main steam safety valves). Once an estimate of thedegraded pump flowrate was obtained, Combustion Engineering (CE) wasasked to evaluate the impact of .this reduced flowrate on the PVNGSaccident analyses. CE responded that they had previously performed some.calculations for a similar .3800 MWt plant. The calculations concludedthat an AFW .flow of 440 gpm would be sufficient to maintain adequate heatremoval for .the limiting Loss of Coolant 'Accident (LOCA) -event and thelimiting non-LOCA event. CE also reviewed the long term cooling functionof the AFW pump for the natural circulation cooldown event. CEdetermined that a flowrate of not more than 450 gpm would be requiredafter the first hour of the event. For the first hour of the event, theexisting inventory of the steam generators along with the reduced AFW

pump flow is sufficient for decay heat removal. In conclusion, ANPP'seva].uatian has gravirled confidence |;hat Ne ~3ant mijn respond adequatelyto the postulated .accidents assuming the degraded AFW pump performanceassociated with the loss of the fourth stage impeller. Additionally,

4IIC I OIIM 3454<9 83I

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NRC Form 344A19 83 I

LICENSEE EVENT REPORT (LERI TEXT CONTINUATIONV4. NUCLEAR REOVLATORY COMMISSION

APPROVEO OMB NO 3150 OIBSEXPIRES: B/31/BB

FACILITYNAME III

Palo Verde Unit 1

TEKT lifmore soece ls reowed, ope oorormol lYITc Form 3RLABIIITI

OOCKET NVMBER 121

o s o o o 5 28 88

LER NUMBER IBI

SEQUENTIALNUM EA

0 1 3

REVISIONNUM SA

0 0 15oF17

NAC I 0AM 544k19 43I

ANPP and the independent pump consultant believe that the degradedpump will be capable of continuing to deliver the degraded flow foran extended period of time following the loss of the fourth stageimpeller. This-is supported by the fact that the essential AFW pumpwas started twice for troubleshooting immediately following thefourth stage impeller failure. The pump was operated for a total of30 minutes and an engineer (utility, non-'licensed) was present forboth runs. The engineer did not observe any abnormalities, unusualnoises, or increased vibrations from the pump.

.ANPP also evaluated the safety consequences and implications,resulting from a total loss of AFW pump function. As a result of thefailure mode. described above (i.e. environmental cracking), ANPPdetermined that the pump's throttle bushing sleeve is susceptible tothe same failure scenario in developing a crack. As evidenced by thefailure which occurred at South Texas Project, it is evident that athrottle bushing failure could result in pump seizure; however, thecompleted complete failure of an AFW pump has not been observed.Therefore, ANPP performed a reliability analysis which was based uponthe operating history experienced at Palo Verde and at the same timeconsidered the effects of a complete AFW pump failure.

The AFW pumps have experienced two.failures (i e., degraded flowevents) in approximately 1216 demands, with both failures havingoccurred in Unit l. A statistical analysis of this data wasperformed assuming that .hydrogen embrittlement cracking occursrandomly in time. This reliability analysis conservatively assumedthe total loss of flow from and AFW pump. The essential, motor-drivenAFW .pump was selected for the purpose of determining the largestallowable incremental risk. The results of the analysis indicatethat the incremental risk incurred from operating with this.deficiency for a period of 18 months (i.e., a full cycle ofoperation) is less than that which results from the removal of theessential motor-driven AFW pump from service for 72 hours. TechnicalSpecification 3.7. 1.2 allows one AFW pump to be removed from servicefor 72 hours without requiring a plant shutdown.

Continued operation of the Palo Verde units with the existing AFHpumps does not pose a risk to plant safety; The evaluation of the

- Palo Verde accident analyses provides confidence that -any conceivableaccident can be mitigated in the unlikely event that one AFW pumploses its fourth stage impeller. The reliability analysis has shownthat continued operation for up to a complete refueling cycle doesnot result in a significant risk to public health and safety. Infact, it results in less risk than would be incurred if theessential, motor-driven AFW pump were removed from service for 72Aoura Sue Xo |;he Hew.risk involved ia future pump -fa|.lares .of this

,.type, ANPP does not believe that it is necessary to shutdown the PaloVerde units solely for the. implementation of AFW pump materialchanges.

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l:

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NRC form 38SAIWl31

LICENSEE EVENT REPORT {LER) TEXT CONTINUATIONV.S, NUCLEAR REGULATORY COMMISSION

APPROVEO OMS NO 3150-010CEXPIRES: 8I31/88

fAGILITYNAME ((I

Pa1o Verde Unit 1

TEXT RI moro (Poco II roSIA'rorL rrw rIOoorcIHRC Fomr 388ASI (173

OOCKET NVMSER (11

o 5 o o o

LfR NVMSER (8)

SEQVSNTrALNVM (R

013rrS v rS rO NNMMP(rr

00 16 QF 17

I I I. CORRECTIVE ACTIONS:

This section contains the information requested by 10CFR21 concerning thecorrective action which has been, is being, and will be taken; theorganizations responsible for the corrective action; and the length oftime for accomplishing the corrective action. It should be noted thatthe schedule for completing the corrective action. discussed below doesnot include an "Estimated Completion Date." This information is notavailable since the length of time for accomplishing the correctiveaction is dependent upon the manufacturer's capabilities for provding the"necessary replacement parts and materials. ANPP does however. anticipatethat the corrective action discussed below will be completed by December,31, 1988.

A. Immediate:

As described above, the AFW pumps were repaired and returned toservice.

B. Action to Prevent Recurrence:

BW and ANPP have conducted a comprehensive review of the pumpdesign. The. objective of this effort was to incorporate designchanges which will eliminate the possibility of a failure due to thetwo root causes identified. ANPP has initiated changes to addressmaterial modifications of the stationary and rotating pump parts.The material modifications are being selected to maximize thematerial's resistance to the hydrogen embrittlement phenomena andlower its susceptability to galling -to produce a more forgivingdesign. In addition to the material changes, the keyway design l'-orthe throttle and center sleeves will be optimized to reduce theoperating stresses inherent to the keyway. The modifications to beimplemented include:

i) Stationary parts to be changed to Ni-Resist I|I2.

Rotating parts to be changed to 410 stainless steel with ahardness in the range of 250 to 300 BHN.

Keyway design for the throttle and .center sleeves is to beoptimized. It is noted that "optimized" is intended-to meanthat the fillet radii of the keyways are to be as large aspossible without causing excessive bearing stresses due to thereduced contact area between the key and its mating parts.

iv) Change the key material from 416 to 410 stainless'steel. Thismodification is being considered as w design wnhanc~ment.

4rrc r GrlM SssoIS 83r

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NRC FPIIA 3SSAI943 I LICENSEE EVENT REPORT (LER) TEXT CONTINUATION

U.S. NUCLEAR REGULATORY COMMISS/ON

APPROVEO OMB NO 3/50 010E

EXPIRES: 8/3I /88

FACILITYNAME (II DOCKEt NUMSER l1l

YEAR

LER NUMSER LSI

SEGVENTIALNVMSER

REVISIONNVMSEA

~AGE IS)

Palo Verde Unit 1

tEXT ////np/p EEPCP ///PEPPY. vpp //PI/np/H/I/O %%dnII ALEE/ llt)o s o o o 52 88 8 0 1 3 00 17 oF l. 7

These modifications will be implemented in the nine AFW pumps as soon .

as the new rotating elements and necessary supporting parts areavailable from the manufacturer.

One of the identified possible contributing causes of the AFW pumpdegradation is full-flow starts of the AFW pumps. Presently,ful.l.-flow starts of the essential AFW pump occur only duringperformance of Integrated Safeguards (ISG) testing. To eliminatethis potential cause of degradation to the pump, the ISG testprocedure will be revised to eliminate the full-flow pump start. Theessential AFW pump will now .be .started on minimum flowrecirculation. The minimum flow start is also closer to theconditions that the pump will see post-accident due to the fact thatthe AFW pump discharge valves open slowly in relation to theacceleration of the pump.

IV. PREVIOUS SIMILAR EVENTS:

There have been no previous similar events reported in accordance withthe requirements of IOCFR50.73.

NRC I ORM SEEDl9 83/

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Arizona Nuclear Power ProjectP.O. BOX 52034 ~ PHO ENlX, ARIZONA 85072-2034

192-00379-JGH/TOS/DAJJune 3, 1988

U. S. Nuclear Regul atory CommissionNRC Document Control DeskWashington, D AC. 20555

Dear Sirs:

Subject:= Palo Verde Nuclear Generating Station (PVNGS)Unit 1

Docket No. STN 50-528 (License No. NPF-41)Licensee Event Report 88-013-00File: 88-020-404

Attached please find Licensee Event Report (LER) No. 88-013-00 prepared andsubmitted pursuant to 10CFR 50.73. In accordance with 10CFR 50.73(d), we areherewith forwarding a copy of the LER to the Regional Administrator. of theRegion V office.

TJis report is also being submitted pursuant to 10CFR21 and includes- theinformation requested in 10CFR21.21(b)(3). In accordance with10CFR21.21(b)(2'), three copies of this report are being provided to theDirector, Office of Nuclear Reactor Regulation.

If you have any questions, please contact .T. D. Shriver, Compliance Manager at(602) 393-2521.

Very tru y yours,

g,J. G. HaynesVice PresidentNuclear Production

JGH/TDS/DAJ/kj

Attachment

cc: 0. M. DeMichele (all w/a)E. E. Van Brunt, Jr.T. E. Hurley (3 copies)J, B. MartinT. J. PolichE. A. LicitraA. C. GehrINPO Records Center

i l,—

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