foMs.public Servlee Company of Cohndo

VM 16805 WCR 19 1/2, Platteville, Colorado 80651

May 7, 1982Fort St. VrainUnit #1P-82135

Mr. George KuzmyczU. S. Nuclear Regulatory Commission7920 Norfolk Ave.Bethesda, MD 20034

SUBJECT: Fort St. Vrain Unit No. 1Operational Conditons

Dear Mr. Kuzmycz:

In the above referenced letter we outlined our operational problemsconcerning System 46 (liner cooling system) and the need toinvestigate the functional capability of the reserve shutdown system.This letter is being forwarded to update the status of these systems.

System 46 test work was completed and the leak in System 46 wasisolated to one core support floor tube. This tube (F4T21) is inLoop I and is on the top plate of core support floor with the inletand outlet of the tube being on either side of center weld for thetwo halves of the support floor liner. (See attached sketch). Wehave evaluated the leak with reference to the FSAR commitments, andwe have effected the necessary repairs. The tube has been isolatedfrom System 46 and double capped on both the inlet and outlet sidewith the interspace between the double caps being pressurized withpurified helium. Our safety evaluation which supports the workperformed is attached for your information.

With reference to the reserve shutdown system, the control rod driveassembly from Region 19 was removed and replaced. An actual releasetest of boron balls from this control rod drive hopper wassuccessfully conducted in the hot service facility. Since thecontrol rod drive assembly in Region 19 appeared to be the oneassembly most seriously affected by high moisture levels in theprimary coolant, we feel the successful test on the control rod drivehopper is indicative that the reserve shutdown system is functionaland the conditions set forth by Amendment 13 have been satisfied.

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The reactor vessel has been repressurized and we have returned topower operation (approximately 10*o power). We intend to continuewith the rise-to power program.

Very truly yours,

/h~7YikuDon W. Warembourg

. Manager, Nuclear ProductionFort St. Vrain Nuclear

Generating Station

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cc: John T. Collins (Region IV) -

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PUBLIC SERVICE COMPANY OF COLORADOFORT ST. VRAIN NUCl. EAR GENERATING STATICN

6 CR / SCR / PC / TRNO. IS

SAFETY EVALUATION PAGE I*E 8J

TVPE:

E CH ANGE NCTICE 'CN) OVERALL CCHANGE NOTICE (CN) SU8MITTAI. CPROCEDURE CHANGE (FSAR)

C TEMPORARY CONFIGURATICN CSETPCINT CHANGE CTEST RECUEST

CLASSIFICATION: ARE THE SYSTEMIS) EQUIPMENT OR STRUCTURES INVOLVED OR DOES THE ACTIVITY AFFECT:CLASS I E YES C NO ENGINEERED SAFEGUARD C YES E NOSAFE SHUTDCWN E YES C NO PLANT PROTECTIVE SYSTEM C YES E NO

'

SAFETY RELATED E YES C NO SECURITY SYSTEM C YES E NO1

REMARKS

EVALilATIGR~

uSE ADDITIONA4. SHEET 5 IF MEGuaHEO.I

1 OETERMINE WHETHER CA NOT THE ACTIVITY INVOLVEQ IS 10ENTIFIED IN THE F S A R CR TECH SPEC. ;The des 19n features and coeratino orocedures cro- i lPPUCA8LE SEC9CNS 9EVIEWEDuST mEded Tor dealing with lea,Kage or tne core succort floor casing and a PCRV! vi

_

'6iner cooling system tuce are ident1rleo and evaluated in .-5AR 5ections

3.3.2.2, 5.9.2.4, 11.1, Ouestions 3.2 and 11.7, 0.2.2 and Tecnnical ..iSaecification LCO 4.2.14 All FSAR Sections and Technical Soecifications d1C" 'were reviewed. LCO 4.8.1 is also certinent to this activity. L% w. r JC )'

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/.% f r.a t & Lee 4J./A b & '%c.L % e w v4 C YES 3 NO |j 2 CGES THE ACTIVITY RECulRE THAT CHANGE (Si SE MACE TO THE F $ A R CR TECH SPEC 7UST SECTIONS TO SE CHANGED AND THE CHANGES TO SE MACE. _

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3 OETERMINE AMETHER CR NOT THE ACTIVITY INVOLVED IS AN UNREVIEWED SAFETY CUESTICN UTIUZING THEFOLLCWING GulOEUNES.

(A) HAS THE PRCBASIUTY CF CCCURRENCE CR THE CCNSEQUENCES OF AN AC01 CENT CR MALFUNCTICNCF ECulPMENT IMPORTANT TO SAFETY PREVICUSLY EVALUATED IN THE F S A R SEEN INCREASED 7C YES G NO STATE SASIS: Ihe orobabilitV of OCOUr'*ence and the cons @0uencas

of leakage of the core supoort floor casino and a 2CRV liner coolino svstamtube have been thorouchly evaluated, with acceotable casults. in the :SARSections cited under 1, above. This chance notice imolenents the remediesdescribed in the FSAR and thus does not chance any of the evaluations cra-

sented therein. (See attachment)1

(B) HAS THE POSSIBluTY OF AN ACCIDENT CR MAL.8UNCTICN CF A CIFFERENT TYPE *HAN ANY EVALUATICNPREVIOUSLY IN THE F S A R 8EEN CREATED 7 C YES 3 NO STATE 3 ASIS: 'he tVoe Of

malfunctions associated with this activity are thorouchiv evaluated in tneF5AR. This cnance notice imolements remedies described theroin, thus, doesnot create any new tyoe of accident or malfunction.

tC) HAS WE MARGIN OF SAFETY. AS oEFINED IN THE 3ASl3 FOR ANY TECHNICAL SPECIFICATICN OR IN THEFSAR 3EEN REQUCED? C YES 3 NO STATE SASIS: Dis chance confo Ms to

conditions allowed hy the FSAR for full ocwer coeration of the clant and ;

coes not excead anv coerstino condition cemitted under exis-ino tachnical Jsoecifications. |

3CES *HE AC 1VITY APPEAR TO: INVCLVE AN UNREVIEWED SAFETY CUESTICN [ YES 3 NO/ 3E SAFE *Y SIGNIFICANT E VES *10

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S_afety Evaluatio,n

I. Background

Increasing pressure has been observed in the PCRV LinerCooling System (Sys. 46) surge tank during power operation.

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Radiochemical analysis of the system fluid revealed thej presence of fission products. The cause of these conditionsi has been investigated and it has been concluded that a small

flow path exists between the primary coolant and liner .t; cooling tube F4T21 located on the concrete side of the top

surface of the core support floor. The rate of primarycoolant leakage has been conservatively calculated to be 1.3

) pounds per hour based on the observed rate of pressureincrease in the Loop 1 surge tank.

XI. Discussioni

The possibility of core support floor casing leakagei and/or liner cooling tube leaks has been provided for in the

design of the plant and has been thoroughly evaluatedrelative to operability and safety of the plant.

The space inside the core support floor is vented and,

i drained to maintain the pressure in the core support floorat 60 psia or less. The vent and drain cavities were fomedduring the concreting of the core support floor and areconnected to tubes pemanently cast in the concrete androuted through the floor, down the core support columns andto the radioactive gas waste system. (FSAR Sections 3.3.2.2;

' and 5.9.2.4)

The radioactive gas waste system (FSAR Section 11.1) isdesigned to collect, monitor and control the release of4radioactive gases in confonnance with 10 CFR 20. provisionis made in this system to collect any primary coolantleaking into the core support floor (FSAR Section 11.1.2.3).The system has sufficient capacity to permit processing acontinuous leak of 14 lbs/hr of primary coolant from thatsource in addition to the maximtsn gas stream from otherexpected sources, and in the absence of other flows, couldhandle as much as 53 lbs/hr. The actual flow is monitoredand recorded in the control room by a flow recorder (FR-6351). (FSAR Section 11.1.3.4, Reference Design 50-63).The holdup capacity of the radioactive gas waste system isprovided by two 700 ft 3 surge tanks, capable of operatingat 450 psig. Wi th a 14 lb/hr leak, the tanks provide atotal of 30 hours hold up capacity. Beyond 30 hours, theleakage would have to be vented from the plant through thereactor plant ventilation system filters. After the firsttank is filled, its decayed activity would be released whilethe other tank is filling, and so on. However, this mode of

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CN O. . operation is not contemplated and, in any caso, the quantity BY N Mdof makeup helium available would not be sufficient to 7 of N~PAGFcontinue plant operation for more than 40 hours with a leakrate of this magnitude. The normal procedure would be to "* 1'"Y[IIshutdown the reactor in an orderly manner and depressurizethe main loop if such a leak should develop. Even if thereactor is assumed to remain at full power for 40 hours andthe leakage during the 10 hours between 30 hours and 40hours is vented directly from the plant the whole body gama(WBG) dose at the exclusion area boundary would be less than5 millirem (worst short tenn dilution, design primarycoolant activity, 5 m/s wind speed, elevated release with 'downwash) (FSAR Question and Answer 11.7). At currentprimary coolant levels the dose would be a small fraction ofthat value or coversely, a leak rate considerably greatercould be allowed under 10 CFR 20 limitations. Consideringthat current equilibrium primary coolant activity at full

; power is about 1/60th of the design activity level; theallowable leak rate could theoretically be increased by theinverse proportion or 60 times without exceeding 10 CFR 20limits.

The possibility of a core support floor casing leakoccurring in close proximity to a liner cooling tube leakand leading to helium bypassing the vent system and leakinginto the affected cooling water loop has also been

;

considered in the FSAR (Question and Answer 3.2). Thatevaluation was based on the leakage resulting in highpressure ( 140 psig) in that loop and authomatic isolationof all 13 subheaders in the loop. The portion of the linercooling system between the inlet and outlet subheader blockvalves is designed for PCRV reference pressure (845 psig)and a safety valve in each loop return header protects therest of the system fran over pressure by relieving water andheltum to the gas wasta vacuum tank, where separation

| occurs.

III. Descriotion of the Modification,

The proposed modi fication consists of plugging theaffected liner cooling tube supply and return (F4T215 andF4T21R) at locations near the outer surface of the PCRV.The plug design utilizes two separate caps to provide a high

,

degree of integrity. The plug design and anaylsis is basedon ASME Code, Section III (1965 Edition) for Class Avessels. Purified helium pressurization is provided to thespace between the caps from the Helium CirculatorPenetration Interspace Pressurization Supply for leak

! moni toring in the same manner as provided for PCRV,

interspaces. The existing flow alann, set at 16.7f/hr, on',

the supply header will alann in the control room if plugleakage exceeds that amount. The purified helium supplypiping and valves are 1-M-2 Class 032 - Purified Helium (845psig and 750 degrees F) and the arrangement and support isin accordance with the requirements for Seismic Class I.

In addi tion, the ends of the plugged tubes extendingbeyond the PCRV concrete will be provided with missileprotection.

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The schematic of the proposed modification is shown in CN / 4%Figure 1. By ## Jd as

PAGE 4 cE YJIV. Evaluation ,m m.a.-

... . . . - . -

A. PCRV Liner Cooling System

To protect the core support floor from damaging heat,the outer surfaces of the structure are lined with a themal

| barrier. The limited quantity of heat which passes throughthe thennal barrier is removed by a system of cooling tubeswelded to the concrete side of the steel plate casing. .During normal reactor operation the thennal barrier andliner cooling system together maintain the casing a meantemperature of 130 degrees F, and :naintain the adjacentconcrete wi thin 150 degrees F, except in identifiedlocalized areas. The liner cooling system consists of twoindependent loops. Al ternate tubes are connected todifferent loops and the water flows in opposite directions.The design heat removal capaci ty of each loop isapproximately twice the total expected heat flux.

The loss of one cooling tube in any set of six on thecore support floor top casing results in acceptable linerand concrete temperatures within the limiting temperature of250 degrees F and reactor operation at full power isallowed. (FSAR Section 5.9.2.4). The FSAR (Section5.9.2.4) also states that if a tube cannot be restored toservice , the adjacent tubes will be monitored continuouslyand an alann will be set to indicate to the operator ifblockage of an adjacent tube has occurred. If the blockageis confirmed and can not be rectified within a few hours theplant would have to be shutdown under existing TechnicalSpecifications (LCO 4.2.14). These requirements will beimplemented by plant administrative procedures.

Furthermore, the ability of.the core support floor tosupport the core during a postulated loss of forcedcirculation (LOFC) accident compounded by complete loss ofcooling water to the core support floor has been comfirmed(FSAR Appendix 0.2.2.3).

Thus, the probability of occurence and consequences ofplugging a single PCRV cooling tube have been described inthe FSAR and have been found to be acceptable. Thisnotification does not affect the previous analyses in thatregard.

Since the possibility of having a small number of PCRVliner cooling tubes out of service has been previouslydescribed in the FSAR, (Section 5.9.2.4) this modificationdoes not create the possibility of a new type of accident.

The FSAR and Technical Specification margins of safetyapplicable to this system consist of redundant loops, excessdesign heat removal capaci ty and the prohibi tion ofoperation if two adjacent tubes are out of service. Theplugging of a single tube does not reduce these safetyma rgins.

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CN MM f**8 Gas Waste System BY J. A 7d*>PAGE < af JJThe radioactive gas waste system is designed as

described in the Discussion above to collect, monitor and ' " "o. m m m

control the release of primary coolant leakage through the - ~ ~ - ' - -core support floor casing. Since the observed flow rate andprimary cool:nt activity are well within the design criteriaof the gas waste system, there are no new safetyconsiderations with recard to this system.

The probability and consequences of primary coolantleakage through the core support floor casing have beenanalyzed and found to be acceptable. This modification has

.

no effect on that aspect of plant operation.

Since the possibility of leakage through the coresupport floor casing has been described in the FSAR(Sections 11.1, 3.2 and Questions and Answers 3.2 and 11.7),the occurrence of the described condition does not createi -

! the possibility of any new type of accident or malfunction.

Technical Specification LCO 4.8.1 defines theconditions necessary to keep radioactive releases from theplant vent and liquid waste system as low as practicable andin any event within the limits of 10 CFR 20 and, thus,establishes the margins of safety relative to operation ofthe Gas Waste System. This modification does not proposeoperation outside the limitations imposed by that Technical

' Specification and, thus, does not reduce the margin ofsafety as defined therein.

C. Core Suocort Floor Vent and Orain System

The core support floor vent and drain system isdesigned, as described in the Discussion above, to collectleakage into the interior of the core support floorstructure and route it to the gas waste system. Theexistence of such leakage within the operational capabilityof the gas waste system to process it has no increased ornew safety implications.

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D. Containment

The proposed modification does not affect the existenceof concurrent leaks in both the core support floor casingand PCRV liner cooling tube F4T21. Therefore it isnecessary to consider the possibility that the plugged endsof the tube , which extend a short distance (10 inches)beyond the PCRV concrete into the Reactor buildingatmosphere, may contain primary coolant. Although theplugged tube ends are well shielded fran missiles by theprotective covers , a redundant pressure boundary is notprovided. This is acceptable on the following basis:helium sampling lines containing primary coolant do not havea redundant pressure boundary. The FSAR identifies the

,

rupture of one of the 1/4 inch helium sampling lines inSection 14.7, which results in a primary coolant leak rateof 18 lbs per hour. Leak rate test data taken on theleakage flow path from the PCRV through the core supportfloor casing into the PCRV liner cooling tube F4T21

__ - . . _ . u _ ____. ._. . _ . _ _ _ _ _ _ . _ . . _ _ _- _ ___

indicates tha leak rata to be much less than 18 lbs perhour. Several leak rate tests have detennined actual SY f 4 J.Mleakage to be 1.3 lbs per hour. Conservative calculations PAGE 7 a[8Jindicate that at 100% power, with normal operating PCRV = % me.m.pressure (700 psia) leakage flow rate wuld be less than 3.0 ~~ - -1lbs per hour, assuming a complete shear of PCRV linercooling tube F4T21 at the PCRV exterior surface. Theconsequences of a single failure at either end of theplugged PCRV liner cooling tube, postulated to be a grossrupture or shear, would thus not exceed the consequences ofa ruptu re of a primary coolant helium sampling lineidentified in FSAR Section 14.7. The probability of leakage -or rupture of the PCRV liner cooling tube F4T21 plugged pipestubs external to the PCRV is less than the probability ofrupture of a primary coolant helium sampling line. Theprobability of failure of a primary coolant sampling line,

, ,

though low, is somewhat greatar due to its greater length.

No new accidents relating to containment are created bythis modification. Primary coolant leaks are discussed in

| FSAR Sections 14.7 and 14.8. The maximum credible accident,shear of the 2 inch diameter helium purificationregeneration line coupled with failure of an interlockedvalve to close followed by failure of operator to close thevalve upstream of the leak, results in an initial primarycoolant leak rate of 3.4 lbs per second (12,240 lbs perhour). This accident results in doses orders of magnitudebelow the guidelines of 10 CFR 100 even assuming design,

'

level primary coolant circulating activity. Postulatedshear of a plugged stub of PCRV liner cooling tube F4T21,resulting in a primary coolant leak rate of less than 18 lbsper hour, does not prevent shutdown and cooldown of thereactor, nor would it result in an unacceptable dose rate at,

| the exclusion area boundary.:

|ihe margin of safety associated with containment is not

! reduced since any primary coolant leakage resulting from afailure of PCRV liner cooling tube F4T21, external to thePCRV will not exceed leakage resulting frcm a rupture of aprimary coolant helium sampling line (18 lbs per hour). Itis very unlikely that the crack in the core support floorcasing, which serves to limit any primary coolant leakage toPCRV liner cooling tube F4T21, will increase in size. Thecore support floor casing was constructed from the samematerial used in the PCRV cavity liner. FSAR Section5.7.2.2 states "The liner material s have an initial nilductility transition temperature (NOT) of at least minus 60

,

degrees F wnich is 160 degrees F below the minimum operatingtemperature. The 160 degrees F value allows for a shift inthe NOT of 100 degrees F and provides for operation abovethe fracture transition elastic temperature (FTE NDT + 60degrees F). This provision will ensure that crackpropagation in the liner at any tensile membrane stress upt

"

| to yield stress would be incredible Based on the...extemely low probability of crack propagation in the coresupport floor casing, it is highly unlikely the primarycoolant helium leak rate through this casing crack, into

,

PCRV liner cooling tube F4T21, to atmosphere (assuming gross!failure of a plug and cap assembly or F4T21 tube wallexternal to the PCRV) would exceed 18 lbs per hour in an

.- _

!

CN iY46 '"accidant. Thus tha double closure, plug and tube cap is BYygM jadequate to insure safety in the short term. In the long PAGE l d 88tem, a set of double isolation valves will be installed onboth ends of tube F4T21, with associated piping. This will 'm =. m. -provide the capability for monitoring leakage flow rate from

-- ----

the core support floor casing crack into the PCRV linercooling tube F4T21 to insure the primary coolant leakageflow rate (which would exist if tube F4T21 failed by grossrupture or shear) remains less than 18 lbs per hour. Thisinstallation will pemit leak monitoring to identify any

.long tem degradation of the core support floor casing leak

| and liner cooling tube F4T21 pressure boundary. ,

10 CFR 50.55a, Footnote 2, provides an exemption fromCode requirements for components connected to the primarycoolant pressure boundary provided that in the event ofpostulated failure of the component during nomal operation,the reactor can be shutdown and cooled down in an orderlymanner. According to General Atomic Company, the currentlarge HTGR design criteria makes use of this exemption forreactor coch:.c lines one square inch in flow area and

i smaller and only requires single pressure boundary andisolation in such cases. Analysis of Fort S t. Vrain hasshown that the reactor can be shut down and cooled down inan orderly manner with continuous discharge of primarycoolant through a one inch pipe.

E. Core Suocort Floor Integrity

Leakage of primary coolant through the core supportfloor casing, within the limit described in the FSAR, i.e.,up to 14 lbs/hr, has no significant damaging effect on thecore support floor. As previously discussed, the ventsystem is designed for just such an eventuality and fullpower reactor operation is permitted without increasing theprobabili ty or consequences of any accidents, creatingdifferent types of accidents or reducing the margin ofsafe ty.

Likewise, the plugging of a single liner cooling tubehas been evaluated in the FSAR and found to be acceptablefor full power operation without increasing the probabilityor consequences of accidents, creating di f ferent types ofaccidents or reducing the margin of safety. In fact, FSARanalysis of a loss of Forced Circulation (LOFC) accidentcompounded by the complete loss of water cooling to the coresupport floor confims the ability of the core support floor

,

| to support the core, wnich is its only safety function.(FSARSection0.2.2)

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