Advises that util will implement augmented vibration ..., Study notes of Design

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Arizona Nuclear Power Project
P.O. BOX 52034 ~PHOENIX. ARIZONA85072-2034
Docket Nos. STN 50-528/529/530
November 5, 1987
161-00647-EEVB/JRP
U.S. Nuclear Regulatory Commission
Washington, D.C. 20555
Attn: Document Control Desk
References: (1)'ette'r from J. G. Haynes, ANPP, to U.S. NRC, dated
October 8, 1987, 161-00562-JGH/JRP.
(2) Letter from J. G. Haynes, ANPP, to U.S. NRC, dated
October 21, 1987, 161-00602-JGH/JRP.
(3) Letter from E. Van Brunt, ANPP, to U.S'. NRC, dated
October 24, 1987, 161-00609-EEVB/WFQ
(4) Letter from J. G. Haynes, ANPP, to U.S. NRC, dated
October 29, 1987, 161-00616-JGH/JRP
Dear Sirs:
Subject: Palo Verde Nuclear Generating Station (PVNGS)
Units 1, 2and 3
Reactor Coolant Pump Shafts
File: 87-A-056-026
The referenced letters discuss ANPP's plan of action for the reactor coolant
pump (RCP) shafts at PVNGS. In ameeting held with the staff on October 24,
1987, ANPP agreed to conditions of the NRC's confirmatory order modifying the
Unit 2license. This agreement was transmitted to the NRC by Reference 3.
As aresult of the meeting held in your offices on November 4, 1987,
concerning the PVNGS RCP shafts, we agree to take the following actions to
allow the continued operation of PVNGS Unit 2.
We will implement an augmented vibration monitoring program for each of the
four reactor coolant pumps that includes the following elements:
1. Every four hours, monitor and record the vibration data on each of the
four reactor coolant pumps.
2. On adaily basis, perform an evaluation of the pump vibration data
contained in 1. above by using an appropriately qualified engineering
individual.
3. When any one vibration monitor on the reactor coolant pumps indicates a
vibration level of 8mils or greater, the Nuclear Regulatory Commission
shall be notified within four hours via the Emergency Notification
System.
~BX111aa12B 8/1zo qgal
PDR ADOCK 050
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Arizona Nuclear Power Project

P.O. BOX 52034 ~^ PHOENIX. ARIZONA85072-

Docket Nos. STN 50-528/529/

November (^) 5, 1987 161-00647-EEVB/JRP

U.S. Nuclear (^) Regulatory Commission

Washington, D.C. 20555

Attn: (^) Document Control Desk References: (1)'ette'r^ from J. G. (^) Haynes, ANPP, to (^) U.S. NRC, dated October (^) 8, 1987, 161-00562-JGH/JRP. (2) Letter^ from^ J.^ G.^ Haynes, ANPP, to U.S. (^) NRC, dated

October 21, 1987, 161-00602-JGH/JRP.

(3) Letter^ from E. Van Brunt, (^) ANPP, to U.S'. (^) NRC, dated

October 24, 1987, 161-00609-EEVB/WFQ

(4) Letter^ from^ J. G. Haynes, ANPP, to U.S. (^) NRC, dated

October 29, 1987, 161-00616-JGH/JRP

Dear (^) Sirs: Subject: Palo Verde Nuclear (^) Generating Station (PVNGS) Units (^) 1, 2 and 3 Reactor Coolant (^) Pump Shafts File: 87-A-056- The referenced letters (^) discuss ANPP's (^) plan of action (^) for the reactor coolant

pump (RCP) shafts at PVNGS. In a meeting held with the staff on October 24,

1987, ANPP agreed to conditions (^) of the NRC's (^) confirmatory order modifying the Unit 2 license. This (^) agreement was transmitted (^) to the NRC (^) by Reference (^) 3. As (^) a result of the meeting held (^) in your offices on November (^) 4, 1987, concerning the (^) PVNGS RCP shafts, we (^) agree to (^) take the following actions to allow (^) the continued (^) operation of PVNGS Unit 2. We will (^) implement an augmented vibration (^) monitoring (^) program for each (^) of the four reactor coolant (^) pumps that (^) includes the following elements:

  1. Every four (^) hours, monitor (^) and record the vibration (^) data on each of the four reactor coolant (^) pumps.
  2. On a daily basis, (^) perform an evaluation of the (^) pump vibration data contained in (^) 1. above (^) by using an (^) appropriately qualified engineering individual.
  3. When (^) any one vibration monitor (^) on the reactor coolant (^) pumps indicates a vibration level of 8 mils (^) or greater, the Nuclear (^) Regulatory Commission shall be notified (^) within four hours via (^) the Emergency Notification System. ~BX111aa12BPDR (^) ADOCK 8/1zo 050 q gal P PD

U.S. NRC Document Control Desk Page 2

161-00647-EEVB/JRP

November (^) 5, 1987

  1. When (^) any one (^) vibration monitor on the reactor coolant (^) pumps indicates a vibration level of 10 mils (^) or greater, within one hour, initiate action to (^) place the .unit in at least HOT STANDBY within -the (^) next six hours, and at least COLD (^) SHUTDOWN within the following (^) thirty hours.
  2. (^) On a daily basis a (^) spectrum analysis shall be .performed on the RCP shaft (^) vibration and evaluated for trends (^) by using an individual qualified in (^) that technique. On detecting a (^) significant change or trend, further analysis will (^) be performed and an evaluation of (^) pump condition will be completed and (^) appropriate action taken As discussed in ANPP (^) presentation to the NRC on November (^) 4, 1987, the future plans are as follows: Unit 1 Modified (^) spare shafts will (^) be installed Extend confirmatory (^) order modifying Unit 2 License to Unit (^1) including spectrum analysis Continue (^) use of Vibration Monitoring (^) System

Units 2 and 3 Extend Confirmatory order (^) modifying Unit 2 License to Unit 3 including spectrum (^) analysis Continue use of Vibration Monitoring (^) System Modified shafts will (^) be installed during the 1988 refueling (^) outage (Unit

  1. and 1989 refueling outage (^) (Unit 3). Based (^) on the information ANPP (^) presented in the referenced letters and as discussed in the (^) aforementioned meetings, it is our conclusion (^) that a reactor

coolant pump shaft failure is not a significant safety concern based on our

accident analysis. and (^) the ,operating experience in (^) Europe and (^) the U.S. Therefore, the continued operation oi PVNGS Unit 2 will (^) not be harmful to the health and (^) safety. of (^) the public.

Enclosed within this letter, please find one copy each of "Response to NRC

Questions on Reactor Coolant (^) Pump Shaft (^) Cracking at PVNGS" (^) and our November 4, 1987, meeting presentation material, "PVNGS (^) RCP Shaft Review". (^) Also,

ss ,e

SUMMARY DISCUSSING WHY UNIT 2 CAN CONTINUE OPERATION

AND UNIT 3 CAN PROCEED WITH LICENSING

Cause: 4 ANPP's (^) comparison of reactor coolant (^) pump (RCP) shaft cracking experience, for shafts (^) identical or similar to (^) PVNGS, has been shared with the NRC Staff. Crack locations for (^) PVNGS and crack locations for a (^) majority of the European plants are confined to the (^) upper end of the (^) keyway and are due to the same (^) root cause. (^) The root cause has been identified. Crack (^) initiation is a result of high stresses in the chrome (^) plating due to thermal and (^) operating stresses. Crack (^) propagation occurs because (^) of high cycle fatigue.

Plan:

A few cracks have been (^) confirmed to exist in two of the Unit 1 shafts. Other PVNGS (^) shafts have not (^) yet been inspected. Further examination (^) is underway on Unit 1. Modified (^) shafts for the three PVNGS Units will be installed (^) during each (^) of the units first refueling (^) outages. Adequate shaft (^) vibration monitoring

capability is in place at PVNGS and previous baseline data exists. Such

vibration (^) monitoring can provide sufficient warning to allow (^) a controlled (^) plant shutdown (^) to prevent a potential shaft break. Shaft breaks (^) are not expected at PVNGS as (^) a result of studying crack propagation rates. The Units 2 and (^3) RCP shafts (^) could be expected to experience shaft crack (^) indications to a lesser degree than the Unit 1 RCP (^) pump shafts due (^) to (^) pump operating conditions.

SUMMARY DISCUSSING WHY UNIT 2 CAN CONTINUE OPERATION

AND UNIT 3 CAN PROCEED WITH LICENSING

(Continued)

~ s )',.-

Therefore, Unit 2 and Unit 3 can (^) safely operate to their first (^) refueling outages in (^) early 1988, and 1989, (^) respectively

Safet (^) Si nificance:

) (^) ~

The PVNGS RCP (^) sheared shaft event is bounded (^) by the FSAR locked rotor (^) analysis. Thereiore, potential occurrences (^) of this (^) type are well within (^) the design and licensing basis. ANPP (^) has performed an additional (^) safety analysis using

realistic assumptions, which resulted in no failed fuel. This a'nalysis con-

firms the (^) actual European experiences (^) with shaft failures which resulted (^) in uncomplicated shutdown, no failed (^) fuel and no breach of the (^) primary system boundary. An analysis of (^) a single failed shaft event for PVNGS resulted (^) in lower combined (^) loads to other (^) pump shafts, therefore, one shaft failure will not initiate another shaft (^) failure.

Conclusion:

A PVNGS (^) RCP shaft failure is not (^) a significant safety concern based (^) on ANPP's accident (^) analysis, the (^) operating experience in (^) Europe, and ANPP answers to the NRC staff (^) questions. Therefore, Unit (^2) may continue operation to its first refueling (^) outage and Unit (^3) may procede with full power licensing and subse- quent operation.

hCTIONS SINCE OCTOBER 24, 1987 MEETIf'!

o PVNGS IMPLEMENTED NRC ORDER ON UNIT 2, (ALSO UNIT 3)

o PVNGS UNIT 1

CONTINUES WITH SHAFT INSPECTIONS

PROCEEDIN('O REPLACE ALL SHAFTS -^ MODIFIED TO ADDRESS ROOT CAUSE

o APS (^) AND NRC TEAI'1S (^) SENT TO OBTAIN EUROPEAl'l (^) EXPERIENCE

o PREPARED ADDITIONAL INFORMATION INCLUDII'!G NRC QUESTIONS RECEIVED ON

1O/23, 10/24, AND 10/29/

EUROPEAN EXPERIENCE, RESULTS OF^ INSPECTIONS, OTHER EFFECTS

PVNGS PUMP PERFORMANCE HISTORY

RESULTS OF ONGOING UNIT 1 PUMP SHAFT INSPECTIO>!<

ANALYSIS OF MARGIN TO NEET NO FAILED FUEL CRITERIA

ANALYSIS OF POTENTIAL FOR '1ULTIPLE^ SHAFT FAILURES

VIBRATION MONITORING

I l 1'

  • if'

P Ion (^) t MWe Na Pomvs^ of Flow m'th

PWR Plants^ with^ KSB^ Pumps Head Speed Motor^ Opeeti m rom kW Seol T oe Power Year

No. of Flawirr/^ j

In'ection water Pipe (D(mm) she Temp.

9iblis (KWBA) 4

(KVG-B)^ Bibhs^ B Ur'ter (^) weser: (KKU) &~J5 M Gr"~nenfeld (KKG-@G) Grcnnde (KWG) Hiilhem-KorlIch (MK) Fbia (^) Verde {ANPP)

1Z

1300 970 1300 1365

1270

247 5O 93

24OOO 95 23870 972

1500 9200 1500 7350 1500 7350 1500 10800 1200 9400

175 175 175

/350^290

290 / 293 l 293 / l350^293 297 l 297 /

1 Stage HS 1 Stage

HS 4/

1 Stage

HS 2/

1 Stage (^) 12/ HS 1 Stage

HS 9/

3 Stage (^) 3/ HD 3 Stage

HD 5/

1 Stage. (^) 10/ HS

3/ 3/ 4/ 4/ 4n1. 6/ 6/

C 0

0 Ol

CL 0

a 6 cn

o ~ x Plf C E

Q

o COo

C

~ C o

E

coo

coo

o 0O 0

oo

p CO

X O I E C 0.— C E C (^) g

HS- (^) HYDROSTATIC SEAL HD- HYDRODYNAMIC SEAL

0 THE DIFFERENT OPERATING PARAf!ETERS DO l'lOT^ IflFLIjENCE C"„ACK^ INITIATION.

HM-l

ll/2/

GEAR COUPLING RADIAL (^) BEARING 5 SEGMENTS THRUST BEARING RADIAL BEARING 5 SEGMENTS

HIRTH-TYPE SPL I NED l.'fUU'LING

7 PADS 11 PADS

GEAR COUPLING (MULHEIM-KARLICH)

RADIAL BEARING 5 SEGMENTS THRUST BEARING RADIAL BEARING 5 SEGMENTS

FLEXIBLE COUPLING (PVNGS)

7 PADS I ll PADS

BIBLIS (^) A, BIBLIS B, UNTERWESER, GOSGEN, GRAFENRHEINFELD GROHNOE HIRTH-TYPE SPLIHED 6$ITBIG

MULHEIM-KARLICH, PVNGS

RADIAL (^) BEARING MATER LUBRICATEO KEY(l

SHAFT SLEEVE STOP (^) SEAL

RADIAL BEARING MATER LUBRICATEO KEYS(2)

SHAFT SLEEVE TOP SEAL

HW-

11/2/

iO

, ~

EUROPEAN METALLURGICAL AND FRACTOGRAPHIC

EVALUATION SU<1NARY

o SHAFT HATERIAL l)X CR ~IX^ Nt NARTENSITIC STAINLESS STEEL WITH CHRONE PLATING

o i'1ECHANICAL^ AND NETALLURCICAL PROPERTIES OF SHAFT NATERIAL WITHIN SPECIFICATION

o FRACTOGRAPHIC EXAMINATION PERFORNED ON S",":-ACt"'.".,FRO!1^ FIVE plp<qS -^ RESULTS CONSISTENT

o FAILURE (^) NODE HIGH CYCLE FATIGUE

o NO EVIDENCE OF HYDROGEN (^) CRACKING OR OTHER AGGREVATING NECHANiSr~ (t OCALIZED CORROSION. ETC. )

o CRACK GRoliTH RATES NOT QUANTIFIED DUE TO FRACTURE SURFACE CONDITION

o ARREST NARKS LOOSELY CORRELATE HITH PUNP OPERATION

HH-

ll/2/

QBAFEN RH El N FELD CRACK PROPAGATION^ IN^ BDP^ SHAFT^ YD^40

SHAF T^ BREAK^ 12/'14/'

(I1XCRO

SHAFT VIBRATION

-DIETERS/ttlLS)

500 /

SHAFT RAO /////////////////////////)

IUS /////////// //////////// /////////// //i////

<OO Z

CRACK

OEPTH

(no}

60 300 ri SO 40 30

  1. 5 f1t 5/'31i'

AVERAGE

CRACK

PROPAGATION 200 /

100 I

V XBRATXON:

8 t1XLS, 2 OAYS

PRXOR TO BREAK

OAYS OF OPERATION

Sinai."

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