Equipment Failure Procedure

PW-51 Reactor Plant Water 10/22/62

A. Makeup Water Supply

• 1. Primary system external leakage is greater than half the available normal make-up (but less than the sustained make-up ability to the primary system).

  NOTE: A sustained makeup of about 4 gpm is available to the primary purification system by using two block orifices in the makeup line; however water requirements in other areas of the plant (e.g., secondary system, intermediate cooling system, other equipment and systems in the machinery space) may be such that 4 gpm cannot be attained, therefore, the sustained makeup must be limited accordingly.

  • a. Because the source of makeup is normally at 270F the temperature of the letdown water going to the ion exchangers may tend to rise above 110F with a normal purification letdown of 20 gpm even though the automatic cooling water control valve for the letdown coolers attempts to compensate for the change. If this situation exists, increase the letdown flow until the temperature of the water to the ion exchanger is corrected.
  • b. Monitor the water inventory particularly in relation to the levels in the pressurizer, buffer seal surge, waste collection tanks (lab waste, waste storage and inner-bottom tanks). Also, closely monitor the PS water quality.
  • c. Determine the source of the leakage and isolate the leakage by switching to alternate equipment selective isolation of piping and equipment.
  • d. Repair the leak before the next reactor startup.
  • e. Should the leakage exceed the sustained makeup ability, shut the reactor down and cool down the primary system using the waste tanks and available makeup for cooldown.
• 2. Intermediate cooling system external leakage is excessively greater than predetermined normal makeup but less than the sustained makeup ability.
  • a. Determine the source of the leakage and isolate the leakage by making visual inspections of accessible equipment outside the containment vessel and secondary shield by switching to alternate equipment, or by isolating piping equipment which does not adversely affect the operation of the reactor plant.
  • b. Monitor the water inventory, particularly in relation to the surge tank and waste collection tanks. Also, monitor the water quality as excessive leakage will tend to reduce the chromate level.
  • c. Repair the leak.
  • d. IF the leakage exceeds the sustained makeup ability, shut the reactor down and cool down the primary system.
• 3. Normal method of makeup to the intermediate cooling system is inoperative.
  • a. Secure makeup and setup the emergency makeup from the discharge of the port feed pump so that makeup may be added through the chemical feed funnel. Tag out the valves on the normal makeup line.
  • b. Monitor the level in the sight glass and the low level alarm on the main console. When a low level is observed in the sight glass or when the low level alarm is actuated, start the port feed pump and open valves CW-159V and CW-87V to fill the tank.

    NOTE: Water from the port feed pump may tend to flash at the chemical feed funnel. Caution should be taken during this operation.

  • c. Make the repairs on the normal makeup line.
  • d. IF the emergency method of makeup should fail with the normal method still inoperative, a temporary hose may be connected from a fresh water source to the surge tank for limited operation.
• 4. External leakage from the secondary system or related systems is greater than the normal makeup but less than the sustained makeup ability.
  • a. Determine the source of the leakage and isolate the leakage by making visual inspections of accessible equipment outside the containment vessel and secondary shield by switching to alternate equipment and by isolating piping and equipment which does not adversely affect the operation of the reactor plant.
  • b. Monitor the water inventory, particularly in relation to the main and auxiliary condenser hot wells, deaerated feedwater heater level, boiler drum levels, and water collection tanks if the leak occurs in the secondary shield or containment vessel.
  • c. Repair the leak.
  • d. IF the leakage exceeds the sustained makeup ability, shut the reactor down and cooldown the primary and secondary systems.

  B. Primary System Water Quality

  • 1. Correction action for over specifications of total solids and dissolved solids.
    • a. Check the primary purification ion exchanger performance, i.e., influent water quality versus effluent water quality.
    • b. With satisfactory ion exchanger performance increase the purification letdown rate and check on the performance at the new rate.
    • c. With unsatisfactory ion exchanger performance change to a new unit, increase the purification letdown rate and check on the performance of the new unit.
    • d. Check on the following:
      • (1) Dissolved oxygen concentration.
      • (2) Hydrogen concentration.
      • (3) Fuel element rupture (solids which could be fission products.)
    • e. Should high total solids concentrations persist following this action, shut down the reactor, cool down the primary system and clean up the loops.
  • 2. Correction action for over or under specifications pH.

    NOTE: Low pH is indicative of high dissolved oxygen content (air exchange), while high pH could possibly be caused by hydrazine residual.

    • a. Check the primary purification ion exchanger performance, i.e., influent water quality vs effluent water quality.
    • b. If the makeup water quality is over specification, increase the purification letdown rate and check the secondary system for the source of contamination.
    • c. With unsatisfactory ion exchanger performance, change to a new unit and increase the purification letdown rate and check on the performance of the new unit.
    • d. With satisfactory ion exchanger performance and makeup water quality, increase the purification letdown rate and check on the performance at the new rate.
    • e. IF the over or under specification still exists over a period of time, continue to operate while endeavoring to ascertain cause.
  • 3. Correction action for over specification on oxygen.
    • a. Check the dissolved hydrogen concentration in the water and check the hydrogen pressure in the buffer seal surge tank. Also, check the oxygen content of the makeup water.
    • b. If either hydrogen concentration or the hydrogen pressure is found to be low, add hydrogen to the buffer seal surge tank.
    • c. If the makeup water is the cause, check the secondary system feedwater and condensate for the source of contamination and correct same.
    • d. IF the over specification continues to exist, continue to operate while endeavoring to ascertain cause, but monitor both oxygen and chloride contents closely and do not permit chlorides to exceed normal specifications.
  • 4. Corrective action for under or over specifications on hydrogen.
    • a. For under specification, check the hydrogen pressure in the buffer seal surge tank and, if necessary, add hydrogen from the hydrogen addition system. An absence of oxygen would indicate sufficient hydrogen.
    • b. For over specification, no action is required. However, check the hydrogen pressure in the buffer seal surge tank and do not add any hydrogen from the hydrogen addition system until the hydrogen concentration and the hydrogen pressure are within the specifications.
  • 5. Corrective action for over specification on chlorides.
    • a. Check the primary purification ion exchange performance, i.e., influent water quality vs effluent water quality, and check the makeup water quality.
    • b. IF the makeup water quality is over specification, secure makeup from the contaminated source and correct the secondary system source of contamination.
    • c. With satisfactory ion exchanger performance, increase the purification letdown rate and check the performance at the new rate.
    • d. With unsatisfactory ion exchanger performance change to a new unit, increase the purification letdown rate and check the performance of the new unit.
    • e. Should high chloride concentrations persist following these actions, shut down the reactor, cool down, and clean up the loop.

  C. Primary System Makeup Water Quality Corrective Action for Over Specifications for Total Dissolved Solids, Chlorides, Oxygen, or Morpholine.

  • 1. Check the primary purification ion exchanger, and if it is satisfactory, no action is required.
  • 2. IF the ion exchanger effluent is not satisfactory, switch to a new unit, and check the effluent of the new unit.
  • 3. These specifications are the same as those for the secondary system feedwater.
  • 4. Should any of the over specifications persist switch to alternate makeup sources. Do not use contaminated makeup sources for sustained periods of time.

  D. Primary System Makeup From Waste Storage Tank Designated as "Filled With PS Water". Corrective Action for Over Specifications for Total Solids and Chlorides.

  • 1. Pump some of the contents of the tank into the other waste tank and fill the PS water tank from the buffer seal surge tank. In order to keep the primary waster inventory from becoming unbalanced, the rate of drainage must not exceed the available normal makeup rate. Generally, if other makeup is available it is better to dump entire tank and refill.
  • 2. If an "off-ship" waste disposal operation is scheduled, pump the contents of the PS water tank to the disposal facility and fill the tank as described in 1. above.
  • 3. If emergency makeup or an emergency cooldown is required while the PS water tank contents are out of specification use this water, as the purification ion exchangers will purify the water. Monitor the ion exchanger effluent and switch to a fresh unit if needed.
  • 4. As an alternate operation to 3. above, the contents of the alternate waste tank should be used if its quality is equal to or better than the off-specification tank (if the over specifications are not too excessive).

  E. Intermediate Cooling Water

  • 1. Corrective action for over specification on total dissolved solids.
    • a. Drain the required amount of water from the system and add an equivalent amount of fresh water makeup.
    • b. After the fresh water addition check that the potassium chromate and pH are within the specifications.

      NOTE: An over specification for total solids may be caused by a salt water leak in the intermediate cooler. However, an over specification in chlorides will occur at the same time. IF such a situation exists, determine the source of the leak and repair same.

  • 2. Corrective action for over specification on chlorides.
    • a. Check the intermediate cooler for a possible salt water leak, and check the quality of the makeup water.
    • b. Drain the required amount of water from the system and add an equivalent amount of fresh water.
    • c. After the fresh water addition, check that the potassium chromate and pH are within specifications.
  • 3. Corrective action for under specifications for potassium chromate.
    • a. Add potassium chromate as required to bring it within the specification. After the adjustment check that the pH is within the range specified below and that dilution is not occurring.
  • 4. Corrective action for over specification on potassium chromate.

    NOTE: Unless an error is made in the amount of chromate added, there should be no normal reason for chromate to be over the specification. IF an over specification exists, a complete investigation, e.g., plugged lines, etc., should be made to ascertain the reason.

  • 5. Corrective action for under and over specification on pH.
    • a. For under specification add the necessary tri-sodium phosphates.
    • b. For over specification add the necessary di-sodium phosphates.

  F. Primary Loop Purification System Effluent and Buffer Seal Water

  • 1. Corrective action for over specification for total solids.
    • a. Check the primary purification ion exchanger performance, i.e., influent water quality vs effluent water quality, and check the makeup water quality.
    • b. IF the makeup water quality is over specification, secure makeup from the contaminated source and correct the secondary system source of contamination.
    • c. With satisfactory ion exchanger performance, increase the purification letdown rate and check the performance at the new rate.
    • d. With unsatisfactory ion exchanger performance change to a new unit, increase the purification letdown rate and check the performance at the new rate.
    • e. Check on oxygen and hydrogen concentrations for fission product release.
    • f. The reactor plant can be operated with high total solids in the ion exchanger effluent as long as the total solids in the primary system water do not exceed the specifications for a sustained period of time.
  • 2. Correction action for over specification on oxygen.
    • a. Check the dissolved hydrogen concentration in the water and check the hydrogen pressure in the buffer seal surge tank. Also, check the oxygen content of the makeup water.
    • b. IF the hydrogen concentration or the hydrogen pressure are found to be low, increase hydrogen pressure in the buffer seal tank.
    • c. If the makeup water is the cause, check the secondary system feedwater and condensate for the source of contamination and correct same.
    • d. IF an over specification continues to exist, continue to operate but monitor the oxygen and chlorides and continue to attempt to find source.
  • 3. Corrective action for under or over specifications on hydrogen.
    • a. For under specification check the hydrogen pressure in the buffer seal surge tank and, if necessary, add hydrogen from the hydrogen addition system. An absence of oxygen would indicate sufficient hydrogen.
    • b. For over specification no action is required. However check the hydrogen pressure in the buffer seal surge tank and do not add any hydrogen from the hydrogen addition system until the hydrogen concentration and the hydrogen pressure are within the specifications.
  • 4. Corrective action for over specification on chlorides.
    • a. Check the primary purification ion exchanger performance, i.e., influent water quality vs effluent water quality, and check the makeup water quality.
    • b. If the makeup water quality is over specification, secure makeup from the contaminated source and correct the secondary system source of contamination.
    • c. With satisfactory ion exchanger performance, increase the purification letdown rate and check the performance at the new rate.
    • d. With unsatisfactory ion exchanger performance change to a new unit, increase the purification letdown rate and check the performance of the new unit.
    • e. Should high chloride concentrations persist following these actions, shut down the reactor, cool down, and clean up the loop.
  • 5. Corrective action for under or over specification on pH.

    NOTE: Low pH is indicative of high dissolved oxygen content (air leakage), while high pH could possibly be caused by hydrazine residual.

    • a. Check the primary purification ion exchanger performance, i.e., influent water quality vs effluent water quality.
    • b. If the makeup water quality is over specification, increase the purification letdown rate and check the secondary system for the source of contamination.
    • c. With unsatisfactory ion exchanger performance, change to a new unit and increase the purification letdown rate and check on the performance of the new unit.
    • d. With satisfactory ion exchanger performance and makeup water quality, increase the purification letdown rate and check on the performance at the new rate.
    • e. IF the over or under specification still exists over a period of time, continue to operate while endeavoring to ascertain cause.

  G. Boiler Water

  • Corrective action for over specification on total solids.
    • a. Check the phosphates and pH in the boiler water and the total solids in the boiler feedwater.
    • b. If the pH and phosphates are over specification, decrease or stop the addition, depending on the degree of over specification and increase the blowdown rate.
    • c. If the pH and phosphates are within their specification range, increase the blowdown rate depending on the degree of over specification. After the total solids are below 500 ppm, check the pH, phosphates, and sulfite concentrations and adjust if necessary.
    • d. If the total solids in the boiler are over specification, increase the blowdown, depending on the degree of over specification, and check the feedwater for the source of contamination, correcting same. This may be due to dissolved oxygen from air inleakage. After the correction has been made it may be necessary to adjust the pH, phosphates and sulfite concentrations.
  • 2. Corrective action for under or over specifications on pH and phosphates.
    • a. For under specifications increase the tri-sodium phosphate chemical addition.
    • b. For over specification increase the di-sodium phosphate chemical addition.
  • 3. Corrective action for over specification on chlorides.
  • a. Increase the blowdown depending on the degree of over specification.
  • b. Check the boiler feedwater quality particularly at the main and auxiliary condenser tube sheet drains, and check the blowdown evaporator.
  • c. Check the effluent of the ion exchangers in the plant water purification system.
  • d. When the blowdown is increases adjustment in the sulfites and phosphate additions may also be required.
  • e. If high concentrations of chloride continue for a sustained period of time, shutdown the reactor, cool down the primary system and reduce the chloride content.
• 4. Corrective action for under and over specification on sodium sulfite.
  • a. For under specification, increase the sodium sulfite addition. Also, check the boiler feedwater for high oxygen content.
  • b. For over specification, decrease or stop the sodium sulfite addition.

H. Boiler Feedwater

• 1. Corrective action for over specifications on high total solids.
  • a. Start recirculation through the "polishing" demineralizer.
  • b. Check on the performance of the plant purification ion exchanger, blowdown, evaporator, tube sheet drains for main and auxiliary condensers and possible carry over from boilers. Also, check the atmospheric drain tank.
  • c. IF the plant purification ion exchanger is performing improperly, switch to the standby unit and check performance of that unit. Replace the resin cartridge in the malfunctioning unit. Also, check the distilled water makeup tank and salt water evaporator.
  • d. If the blowdown evaporation is performing improperly, divert the distillate to the bilge until it is satisfactory, and it may be necessary to drain some of the "bottoms".
  • e. If one of the tube sheet drains for the condensers indicates that it is the source of the trouble, place the contaminated drain system into operation.
  • f. If carry-over from the boilers is the source of the trouble check the water levels in the boilers and check the total dissolved solids in the boiler water.
• 2. Corrective action for over specification on chlorides.

  NOTE: Except for carry-over from the boilers, the possible sources of contamination and the corrective actions are the same as those for total solids in 1. above. Action must take place immediately because detectable chlorides in the feedwater will be concentrated and will result in over specification in the boilers in a very short period of time.

• 3. Corrective action over specifications on oxygen.
  • a. Check performance of the deaerated feedwater tank and the sulfite in the boilers. Also, check the performance of the air ejectors on the main and auxiliary condensers and the main and auxiliary condensers for possible air leaks.
  • b. IF the DFT is performing unsatisfactorily make the necessary corrections to rectify the situation.
  • c. IF one of the air ejectors are performing unsatisfactorily make the necessary adjustments to correct the situation.
• 4. Corrective action for over or under specifications on pH.
  • a. For under specification, increase the morpholine concentration by increasing the rate of addition.
  • b. For over specification reduce the morpholine concentration by reducing or stopping the rate of addition.

I. Plant Water Purification Effluent

• 1. Corrective action for over specifications on chlorides or conductivity.
  • a. Normally, this sampling point will only be checked for conductivity. Should high conductivity develop, the first step will be to determine if this is due to high chlorides.
  • b. Switch to the standby unit and check the salt water, evaporators, boiler feedwater tank and distilled water makeup tank. Replace the resin cartridge in the malfunctioning unit.

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    My text copyright 2020 Tommy Johnson, all rights reserved. I believe the Savannah documentation is property of MARAD or the US government.