05000413/LER-1987-041, Resubmitted Ltr Forwarding LER 87-041-00

Resubmitted Ltr Forwarding LER 87-041-00

ML20147C571
Person / Time
Site:	Catawba
Issue date:	01/04/1988
From:	Tucker H DUKE POWER CO.
To:	NRC OFFICE OF ADMINISTRATION & RESOURCES MANAGEMENT (ARM)
References
NUDOCS 8801190277
Download: ML20147C571 (1)

LER-2087-041, Resubmitted Ltr Forwarding LER 87-041-00

Event date:
Report date:
4132087041R00 - NRC Website

text

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. Resubmitted on 01/04/88.

DUKE POWER GOMPANY P.O. BOX 03180 oHARLOTTE. N.o. 28242 51AL B. TUCKER TELEPHONE

, s . vsos russinewr (704) 073-4531 wuctasa reoownom e December 17, 1987 Document Control Desk U. S. Nuclear Regulatory Commission

. Washington, D. C. 20555

Subject:

Catawba Nuclear Station, Unit 1 Cocket No. 50-413 LER 413/87-41 Gentlemen:

' Pursuant to 10 CFR 50.73 Section (a) (1) and (d), attached is Licensee Event Report 413/87-41 concerning missed Semi-Annual Non-Prelubed Start periodic Technical Specification required tests for Diesel Generators 1B and 2B due to personnel errors. This event was considered to be of no significance with respect to the health and safety of the public.

Very truly yours,

. l44 .. %

Hal B. Tucker JGT/1141/sbn Attachment xc: Dr. J. Nolson Grace American Nuclear Insurers Regional Administrator, Region II c/o Dottie Sherman, ANI Library U. S. Nuclear Regulatory Commission The Exchange, Suite 245 101 Marietta Street, NW, Suite 2900 270 Farmington Avenue Atlanta, Georgia 30323 Farmington, CT 06032 H&M Nuclear Consultants Mr. P. K. Van Doorn 1221 Avenue of the Americas NRC Resident Inspector New York, New York 10020 Catawba Nuclear Static,n L

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On July 16, 1987, while performing Diesel Generator (D/G) 1B Operability Test, and on July 22, 1987, while performing D/G 2B Operability Test, Nuclear Equipment Operators (NEos) performed prelubed D/G starts instead of the required non-prelubed starts and consequently missed the required semi-annual surveillances. Duke power personnel determined this event to be reportable on November 17, 1987.

The surveillances were satisfied on October 7, 1987, for D/G 1B and on November 17, 1987, for D/G 2B. Both Units operated in Mode 1, Power Operation, Mode 2, Startup, Mode 3, Hot Standby, Mode 4, Mot Shutdown, and Mode 5, Cold Shutdown, during the periods in which the surveillances were not performed.

These incidents are attributed to personnel errors. The involved NEOs did not perform the proper step in each procedure and their Supervisors did not discover the error during their reviews.

The surveillance was performed for D/G 2B fcllowing discovery. The surveillance for D/G 1B was found to have been satisfied by a non-prelubed start performed on October 7,1987. These incidents were reviewed with involved personnel with emphasis on attention to detail. Future non-prelubed start requirements will be better identified on the operations Worklist. Offsite power was continuously available throughout the event.

Thehealthandsafetyofthepublicwereunaffectedbythiseventh 290/ 9 %7 See

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01 0 012 Ol5 rexta - um.. - u - c % m mn BACKGROUND:

Each emergency power (EIIS:EK) Diesel Generator (EIIS:DG) (D/G) at Catawba must be started at least once per month to verify that the D/G will be available to provide emergency power to safety related equipment when needed. The purpose of PT/1/A/4350/02B, Diesel Generator 1B Operability Test, and PT/2/A/4350/02B, Diesel Generator 2B Operability Test, is to perform the required Periodic Tests (PT) for D/G 1B and D/G 2B, respectively.

Originally, all D/G start tests at Catawba Nuclear Station were to be "non-prelubed" tests with the engine started from normal standby condition.

Early testing in this manner resulted in several failures of the D/G turbochargers. Industry wide investigation of these failures determined the cause to be repeated starts of Diesels without adequate lubrication at the turbocharger thrust bearings.

Modifications to the oil supply piping were made at Catawba Nuclear Station to resolve the lubrication problem. The resulting configuration consisted of a new line from the dischargo of the existing prelube oil pump (EIIS:P) through an engine contrcl panel operated solenoid valve (EIIS:V), directly to the turbocharger oil supply lines. Before a D/G is operated, the solenoid valve is opened and the prelube oil pump (which runs constantly) lubricates the turbochargers. Because over-oiling these bearings is a possibility, the prelube period is limited to five minutes before engine start.

All scheduled D/G starts are preceded by a turbocharger prelube period except in the following instances:

(1) Once every six months in January and July to meet the surveillance requirement of Technical Specification 4.8.1.1.2.a.4.

(2) When a simulated emergency Engineered Safeguards Features start is performed for testing purposes.

(3) Actual conditions develop which require an auto-start or Control Room originated start.

DESCRIPTION OF INCIDENT:

On July 16, 1987, at approximately 2200 hours0.0255 days <br />0.611 hours <br />0.00364 weeks <br />8.371e-4 months <br />, an Operctions Unit Supervisor directed a Nuclear Equipment Operator (NEO) to perform PT/1/A/4350/02B, Diesel Generator IB Operability Test, as identified on the Operations Worklist. The NEO

! gathered the required materials, performed the required initial checks of the Diesel Generator (D/G) procedures and went to Diesel Room 1B to start the D/G.

While performing the procedure steps, the NEO failed to recognize that step 12.16 was applicable and therefore bypassed this step. This step contains the statement "Perform a non-prelubed start during the first test of the month, in the months of July and January". The NEO mistakenly continued performance of a prelubed start of D/G 1B. He loaded the D/G and secured it after the completion of the one hour run.

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Following the test, the NEO returned to the Control Room to analyze the start data and verify the D/G operated correctly.

During the following night shift, with a new shift on duty, the PT was completed and then given to a different Operations Unit Supervisor and to the Shift Supervisor on duty for their review and approval. On the morning of July 18, 1987, the PT was evaluated for completeness by a Unit 1 Operations Staff Engineer.

On July 22, 1987, an almost identical sequence of events started on D/G 2B. D/G 2B was to be started per PT/2/A/4350/02B, D/G 2B Operability Test, as identified on the Operations Worklist. A different NEO gathered the required materials, performed the checks in the procedure file and proceeded to D/G 2B.

In the Diesel Room, the second NEO went through the steps of the procedure prior to engine start and at 1709 hours0.0198 days <br />0.475 hours <br />0.00283 weeks <br />6.502745e-4 months <br />, N/A'd step 12.16 of the PT which required the engine start to be a non-prolubed start failing to recognize that the step needed to be performed.

The second NEO prelubed the turbochargers, started, and loaded the D/G. When the one hour run was completed, he secured the D/G.

The NEO later returned to the Control Room, evaluated the starting data and made entries in the D/G 2B logbook prior to shift change at 1900 hours0.022 days <br />0.528 hours <br />0.00314 weeks <br />7.2295e-4 months <br />.

On July 24, at 0333 hours0.00385 days <br />0.0925 hours <br />5.505952e-4 weeks <br />1.267065e-4 months <br />, the PT was completed and then given to another Unit Supervisor and a different Shift Supervisor for their review and approval.

On the morning of July 24, 1987, the PT was sent to a Unit 2 Operations Staff Engineer who reviewed the PT for completion.

On October 7, 1987, D/G 1B was tested by Duke Power Performance personnel during Engineered Safeguards Features (ESP) testing. In this testing the D/G was auto-started without prelubing the turbochargers to simulate an emergency start.

The D/G's performance was satisfactory, and it fulfilled the surveillance requirement. .

On the morning of November 17, 1987, when a Unit 2 Operations Staff Engineer was reviewing the D/G Technical Specifications, he noticed the footnote concerning the semi-annual non-prelubed start surveillance. He then proceeded to check the completed Unit 2 pts for correct completion of the surveillances. He discovered that the surveillance requirements had not been satisfied.

The Unit 2 Operations Staf f Engineer then informed the Unit Coordinator, the Shif t Supervisar and the Unit 1 Operations Staf f Engineer of his findings. The Unit 1 Operations Staff Engineer began checking the Unit 1 pts for correct completion of the semi-annual surveillance.

The Shift Supervisor declared D/G 2B inoperable and notified the Compliance Engineer. He then made provisions to have the D/G 2B Operability Test performed including the non-prelubed start procedure. This was completed and the D/G declared operable at 1207 hours0.014 days <br />0.335 hours <br />0.002 weeks <br />4.592635e-4 months <br /> on November 17, 1987.

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0} 0 0 l4 OF 0l5 m w- we, a <mns. ,,,,,oo. mmc w seu swn The Unit 1 Operations Staff Engineer found that the D/G 1B Operability Test of July 16, 1987, did not satisfy the surveillance requirements. He then discovered that the non-prelubed start performed on October 7, 1987, during ESF testing was successful and satisfied the surveillance criteria.

CONCLUSION:

These incidents are attributed to personnel errors. The NEOs did not follow the instructions in the step of the procedures concerning the requirement for a non-prelube start of the D/Gs during the months of July and January.

Additionally the supervisory reviews failed to detect the errors.

Both NEOs were fully qualified on D/G operating procedures at the time of the incidents.

The personnel involved attributed the cause of the missed step to routinely performing a prelubed start and concentration on Diesel Generator parameters at the time the step was signed.

Due to the infrequent requirement for a non-prelubed start and the number of personnel involved in the incident that missed the step while performing the PT and during its review, the Operations Procedures Group has committed to restructure the pts. In the future the NEOs will inspect the D/G logbook and determine whether the turbochargers should be prelubed before going to the Diesel Room.

Technical Specification violations due to Operations personnel errors are considered recurring evento based on Duke Power guidelines. It should be noted that the non-prelube D/G Start Surveillances have not been missed previcusly.

CORRECTIVE ACTION:

SUBSEQUENT (1) The Shift Supervisor declared D/G 2B inoperable.

(2) A non-prelubed start was performed on D/G 2B and D/G 2B was declared operable.

(3) These incidents were reviewed with involved personnel with emphasis on attention to detail.

PLANNED (1) PT/1,2/A/4350/02A,B will be revised so that the need for a non-prelube start will be determined before testing begins.

(2) These incidents will be reviewed at an upcoming Shift Supervisors meeting.

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SAFETY ANALYSIS:

During the period from July 16, 1987, to October 7, 1987, D/G 1B was not non-prelube started as required. However, the D/G performed satisfactorily when tested on October 17, and was fully operable throughout the period, although the surveillance was not performed as required. D/G 1B was inoperable for other reasons during the period. These instances were administratively controlled in compliance with Technical Specifications, except as reported in LER 413/87-33.

D/G 1A and the Unit 1 Turbine Driven Auxiliary Feedwater Pump were never simultaneously inoperable during this period. Also, offsite power was continuously available throughout this period. Therefore, redundant sources of AC power and Auxiliary Feedwater were continuously available to Unit 1 throughout the period.

During the period from July 22, 1987, to November 17, 1987, D/G 2B was not non-prelube started as required. However, the D/G performed satisfactorily when tested on November 17, and was fully operable throughout the period, although the surveillance was not performed as required. D/G 2B was also inoperable for other reasons during the period. These instances were administratively controlled in compliance with Technical Specifications. D/G 2A and the Unit 2 Turbine Driven Auxiliary Feedwater Pump were never simultaneously inoperable during this period.

Also, offsite power was continuously available throughout this period.

Therefore, redundant sources of AC power and Auxiliary Feedwater were continuously available to Unit 2 throughout the period.

These incidents are reportable pursuant to 10 CFR 50.73, Section (a)(2)(1)(B).

The health and safety of the public were unaffected by these incidents.

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