IR 05000259/1973016
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" 'A UNITED STATES o#c g*g ATOMIC ENERGY COMMISSION II (, e p '-
DIRECTORATE OF REGULATORY OPERATIONS REGION ll - Suit E 818
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AT L. A NT A. GEORGI A 30303 RO Inspection Report No. 50-259/73-16 Licensee: Tennessee Valley Authority 818 Power Building Chattanooga, Tennessee 37301 Facility Name: Browns Ferry 1 Docket No.:
50-259 License No.:
DPR-33 Category:
B2 Location: Decatur, Alabama Type of License: 3293 Mwt, BWR (G-E)
l Type of Inspection: Routine, Announced Dates of Inspection: December 10-13, 1973 Dates of Previous Inspection: November 6-8, 1973
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Principal Inspector:
W. S. Little, Reactor Inspector Facilities Test and Startup Branch Accompanying Inspector:
T. N. Epps, Reactor Inspector Facilities Test and Startup Branch
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W. S. Little, Reactor Inspector
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Facilities st and,Startup Branch
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Reviewed by:
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C. E. Murphy, CQief/
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Ddte Facilities Test and Start'up Branch 8604300252 860317
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R0 Rpt. No. 50-259/73-16-2-l SUMMARY OF FINDINGS I. Enforcement Action None i
II. Licensee Action on Previously Identified Enforcement Matters A.
Violations
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1.
Report No. 50-259/73-13, Miscellaneous Violations Awa'iting additional TVA response to the letter to the licensee.
(Details I, paragraph 2)
2.
Report No. 50-259/73-14, Item I.A.l.b, Stack Gas Monitor Resolved (Details I, paragraph 3)
3.
Report No. 50-259/73-14, Item I.A.2.a. Plant Security Resolved (Details I, paragraph 4)
4.
Report No. 50-259/73-15, Item I.A.l.a, Radwaste Release Resolved (Details I, paragraph 5)
III. New Unresolved Items 73-16/1 High Pressure Coolant Inj ection (HPCI) and Reactor Core Isolation
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Cooling (RCIC) Inoperability Following Complete Loss of AC Power
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Test (Abnormal Occurrence BFA0-7334)
l HPCI and RCIC inoperable until manually reset following loss o(
AC power test on November 10, 1973. Corrective action is not
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complete.
(Details I, paragraph 6)
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73-16/2 HPCI Inverter Failure (Abnormal Occurrence BFAO-7336)
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i Inverter power supply fuse failed on November 21, 1973, while surveillance testing the condensate header low level switches.
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(Details I, paragraph 7)
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RO Rpt. No. 50-259/73-16-3-73-16/3 ADS Permissive, Pressure Switch Setpoint Drift (Abnormal Occurrence BFAO-7337)
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Surveillance testing on November 14, 1973, resulted in pressure switches operating at 225 psig rather than 185 10 psig.
(Details I, paragraph 8)
73-16/4 RCIC and HPCI Failure (Abnormal Occurrence BFAO-7338)
On November 15, 1973, following the initiation of the loss of turbine generator and offsite power startup test at 25% power, the RCIC steam valve failed to open and the HPCI isolated when manually started. Cause of the HPCI isolation remains unknown.
(Details I, paragraph 9)
73-16/5 HPCI Steam Flow Pressure Switch Setpoint Drift (Abnormal Occurrence BFAO-7340)
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During surveillance testing, one set of contacts in each of
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two pressure switches operated at 92.5 and 96.0 psid rather than < 90 psid. The other set of contacts in each switch tested satisfactorily and the logic would have performed its intended function.
These switches are Barton Model 288.
Accelerated testing is continuing.
(Details I, paragraph 10)
73-16/6 Malfunction of HPCI Level Switch (Abnormal Occurence BFAO-7342)
The level switch which relieves the HPCI suction from the condensate header to the torus was actuated when a relief
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valve operated during a startup test on November 15-16, 1973.
The cause is under investigation.
(Details I, paragraph 11)
73-16/7 Torus Vibration (Abnormal Occurrence BFAO-7343)
During startup testing of the relief valves on November 18, 1973, significant noise and more than desirable vibration was detect-ed.
TVA initiated extensive torus vibration testing which is still in process.
(Details I, paragraph 12)
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R0 Rpt. No. 50-259/73-16-4-
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73-16/8 Main Steamline High Flow Pressure Switch Setpoint Drift (Abnormal Occurrence BFAO-7344)
During a surveillance test on November 30, 1973, one of sixteen pressure switches did not operate due to a bellows leak. The 10-day report had not been received at the time of this inspection and this item will be followed up during the next inspection.
73-16/9 Core Spray Sparger to Reactor Vessel Pressure Switches (Abnormal Occurrence BFAO-7345)
During routine daily instrument checks, the two d/p indicating switches (PdIs-75-28 and -75-56) were observed downscale rather than the required 5 1.5 psid. TVA will submit a 10-dcy report on this item.
73-16/10 LPCIS Pressure Switch Setpoint Error (Abnormal Occurrence BEAO-73-46)
During a surveillance test on December 7, 1973, one of the l
pressure switches (Barton Model 288) was found to operate at 2.2 psig rather than the required < 2.0 psig. TVA will submit a 10-day abnormal occurrence on this item.
(Details I, paragraph 10)
IV. Status of Previously Reported Unresolved Items 73-15/1 Unanalyzed Liquid Release To The River (Abnormal Occurrence BFAO-7330)
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Resolved (Details I, paragraph 5)
l 73-14/1 Failure of Stack Gas Monitor Pump Motor (Abnormal Occurrence
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BEAO-73-16, and -7324)
Resolved (Details I, paragraph 3)
73-14/2 Isolation Valve Failure (Abnormal Occurrence BFAO-7319)
Resolution awalts the completion of accelerated surveillance j
testing. Followup will continue during the next inspection.
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R0 Rpt. No. 50-259/73-16-5-73-14/3 Drywell Pressure Switch'Setpoint Error (Abnormal Occurrence BEAO-7321)
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Resolved (Details I, paragraph 15)
73-14/4, Reactor Water Level Switch Setpoint Error (Abnormal Occurrences BFAO-7322, -7333, -7341)
Resolution awaits the results of the accelerated surveillance testing of the recently modified Barton Model 288 pressure switches.
(Details I, paragraph 10)
73-14/7 Low Pressure Coolant Inj ection System (LPCIS) Pressure Switch Setpoint Error (Abnormal Occurrences BFAO-7326 and -7346)
l Resolution awaits the results of the accelerated surveillance
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testing of the recently modified Barton Model 288 pressure switches.
(Details I, paragraph 10)-
t 73-14/8 Jet Pump Pressure Switch Setpoint Error (Abnormal Occurrence DAO-7327)
Resolution awaits the results of the accelerated surveillance testing of the recently modified Barton Model 288 pressure I
switches.
(Details I, paragraph 10)
73-13/3 Reactor Core Isalation Cooling System (RCICS) High Steam Flow Pressure Switch Setpoint (Abnormal Occurrence BEAO-7313)
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Resolution awaits the results of the accelerated surveillance
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testing of the recently modified Barton Model 288 pressure switches.
(Details I, paragraph 10)
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73-14/5 Condenser Low Vacuum Switch Setpoint Error (Abnormal Occurrences
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BFAO-7323, -7331, and -7339)
Accelerated testing is in progress and resolution awaits testing l
completion.
73-14/6 Accidental Isolation of the High Pressure Coolant Injection j
System (HPCIS) (Abnormal Occurrence BFAO-7325)
Resolved.
(Details I, paragraph 13)
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R0 Rpt. No. 50-259/73-16-6-73-14/9 Inoperative HPCI Level Switches (Abnormal Occurrences BFAO-7328 and -7332)
Resolved.
(Details I, paragraph 14)
Valve Wall Thickness (AEC Letter to TVA dated June 30, 1972)
The TVA final report promised by November 15, 1973, was not yet complete. DED representatives, subsequent to the inspection, committed to having the final report ready for AEC review in Knoxville on December 28, 1973.
V. Design Changes j
None VI. Unusual Occurrences None
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VII. Management Interview On December 13, 1973, the inspection results were discussed with the following:
Tennessee Valley Authority (TVA)
Division of Power Production (DPP)
H. J. Green - Plant Superintendent J. B. Studdard - Operations Supervisor R. G. Metke - Plant Results Supervisor J. Dewease - Assistant Plant Results Supervisor W. A. Roberts, Jr. - Maintenance Supervisor
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J. R. Pittman - Instrument Engineer I
W. D. Poling - Quality Assurance (Chattanooga)
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d RO Rpt. No. 50-259/73-16-7-Division of Construction (DEC)
R. T. Hathcote - Proj ect Manager M. M. Price - Construction Engineer C. G. Holmes - Supervisor, Construction Engineering Section G. B. Livingston - Electrical Engineering Supervisor B. Gant - Assistant Construction Engineer M. N. Sawyer - Startup and Test.Section Supervisor E. Hilgeman - Construction Administration Division of Design (DED)
A. L. Mazzetti - Quality Assurance Office of Engineering Design and Construction (OEDC)
R. W. Dibeler - Quality Assurance Division of Power Resource Planning (DPRP)
L. H. Coots - Quality Assurance General Electric Company (G-E)
J. D. Martin - Operations Superintendent J. E. Nichols - Site Principal Mechanical Engineer J. L. Perreault - Startup Test Engineer The following items were discussed:
A.
Unresolved and Enforcement Items
The status of these items in Sections II, III, and IV of this report was discussed.
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B.
Abnormal Occurrences The inspector stated that he had looked at plant records to confirm that commitments made in abnormal occurrence reports were being met.
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RO Rpt. No. 50-259/73-16-8-The inspector expressed' concern that DPP appeared to not have a
. good plan for keeping up with these commitments. This will be followed up on in future inspections.
C.
Control Rod Inspection The inspector stated that all future shipments of control rods to the site should be inspected as required by R0B 73-5.
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R0 Report No. 50-259/73-16 I-l
//?[7Af DETAILS I Prepared by:
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. S. Little
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Reactor Inspector Facilities Test and Startup Branch Dates of Inspection: Dece er 10-13, 1973 Reviewed by:
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C. E. Mutthy,sChief P ga~fe Facilities Test and Startup Branch 1.
Persons Contacted Tennessee Valley Authority H. J. Green - Plant Superintendent A. Qualls - Assistant Operations Supervisor W. A. Roberts - Maintenance Supervisor J. Dewease - Assistant Results Section Supervisor T. Cox - Assistant Maintenance Supervisor, Electrical J. Hodges - Engineering Aide J. Pittman - Instrument Engineer 2.
Report No. 50-259/73-13 - Violations At the time of the inspection, the promised additional response to that in TVA's letter dated October 23, 1973, had not been received. The following information concerning these violations-was obtained:
Paragraph 1.A.l.a. - Failure to Certify Relief Valve Setpoints The inspector verified that'the setpoint verifications were at the site during the inspection of October 16-19, 1973. The changes to plant procedures described in TVA's letter of Octobe.r 23, 1973, will be verified by the inspector during the next inspection.
Paragraph 1. A.l.b. - Nonconforming Drywell Head Gasket DPP representatives told the inspector that the plant storeroom will be audited by January 1974 to ensure proper material segregation and identification.
The results of the audit will be reviewed by the inspector during the next inspectio _ _
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i R0 Report No. 50-259/73-16 I-2
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Stad;, Gas Monitor Failure Abnormal Occurrence Report No. BFAO-7324 described the followit.g corrective action: Rewind the sample pump motors using Class H insulation rather than low temperature insulation, change the
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sample pump motor power supply cable size from No. 8 to No.1/0, and change the motor circuitry design such that each motor is separately fused. The inspector confirmed that the first two of the above corrective actiona have been completed and operation since that time has not resulted in any sample pump motor failures.
The circuit modifications to separately fuse each motor are scheduled for the plant shutdown which began on December 12, 1973.
The inspector stated that he had no further questions on this item.
4.
Plant Security TVA's letter of December 5,1973, responded to the violation described in RO Inspection Report No. 50-259/73-14. The inspector confirmed that TVA's corrective action had been implemented; e.g.,
Two public safety officers were assigned to the gatehouse during the 7 a.m. through 3 p.m. shift to assure that the gatehouse will be manned as required by the Technical Specifications and BF-ISI-1 during periods of heavy traffic through the gatehouse and the vehicular gate. The inspector stated that he had no further questions.
5.
Unanalyzed Liquid Release to the River Abnormal Occurrence Report No. BFEAO-7330 stated that procedures would be changed to prohibit the recycling of a sample tank during a release from another sample tank. The inspector reviewed OI-77,
"Radwaste Disposal System," operating procedure and found that the appropriate revisions had been made. The inspector stated that he had no further questions on this item.
6.
RCIC and HPCI Inoperability Following a Complete Loss of AC Power Test Abnormal Occurrence Report No. BFAO-7334 described corrective action
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to prevent the recurrence of similar failures. The inspector confirmed that the manual reset requirement of the tripping logic l
had been removed and a diverse power source provided to one of the relays. A DPP representative said that the DED design report on other control schemes and tripping logic changes was not yet at i
the site, but they planned to have DED's recommendations and approvals in time to complete the remaining modifications during i
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this c7 ant shutdown. The inspector will follow up on this item
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during the next inspection, l
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R0 Report No. 50-259/73-16 I-3 i
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HPCI Inverter Power Supply Fuse Failure
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Abnormal Occurrence Report No. BFAO-7336 - A DPP representative e
said that additional tests will be run during this shutdown to make sure that the source of the high voltage spikes has been
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eliminated. The inspector will follow up on this item during
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i the next inspection.
8.
ADS Permissive Pressure Switch Setpoint Drift i
Abnormal Occurrence Report No. BFA0-7337 said that no reason for
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the setpoint drift of the Mecoid Model DA 7943-804 switches-could be found. They committed to increasing the frequency of the
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i surveillance tests from monthly to biweekly until three consecutive satisfactory tests are performed. The inspector examined the surveillance test record and found that these switches were
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successfully tested for the first time at the accelerated frequency on November 28, 1973. Followup will be continued during the next inspection.
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Abnormal Occurrence Report No. 7338 described the failure of these q
systems to properly operate when manually initiated. Following a
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loss of turbine generator and offsite source test, the inspector confirmed that the cause of tne RCIC failure to start was corrected.
j Several tests have subsequently been run on the HPCI system to i
determine why it isolated when manually initiated. DPP representatives
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l said that they have not been able to repeat the hPCI system isolation i
j and did not yet know why it occurred. TVA's investigation is contin-i uing and the inspector will follow up on this item during the next j
inspection.
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10.
Pressure Switch Setpoint Drift - Barton Model 288
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i TVA has reported ten abnormal occurrences resulting from setpoints
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drifting excessively for Barton Models 288 and 288A pressure switches.
I DPP representatives told the inspector that Barton representatives have been at the site and reviewed the pressure switch' installations i
and have reviewed the TVA calibration procedures in an effort to j
determine what must be done to minimize and hopefully to prevent
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excessive setpoint drift. Barton had subsequently recommended that i
a new setpoint locking device be added to all of the Barton Models l
288 and 288A pressure switches. DPP representatives told the
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inspector that the new locking device had been installed on all the
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l RO Report No. 50-259/73-16 I-4 pressure switches used in the safety related systems and covered by the technical specifications. The inspector looked at a pressure switch that had both the new and old locking device. It was apparent that the new device would maintain better control over the setpoints and result in less drift. DPP representatives stated that accelerated surveillance testing is in progress and results to date indicate that the new locking device is minimizing setpoint drift. The inspector stated that he will continue to follow up on this problem during the next inspection.
11.
Malfunction of HPCI Level Switch Abnormal Occurrence Report No. BFA0-7342 reported that the level switch which transfers HPCI suction from the condensate storage tank was erroneously actuated during a relief valve actuation. DPP representatives said that additional relief valve tests are scheduled following the plant startup after the current shutdown and the effect of wave action cnd vibration on the level switch will be investigated in order to arrive at the necessary corrective action. They stated that the DED study to eliminate this problem will be completed after these tests. The inspector stated that he will follow up on this problem during the next inspection.
12.
Torus Vibration Abnormal Occurrence Report No. BFA0-7343 - TVA had completed approximately two weeks of tests to study torus vibration caused by relief valve blowdown. DPP representatives told the inspector that an interim report of the test results to-date will be submitted.to the AEC by December 17, 1973. TVA plans to permanently shim the torus support feet during this shutdown and run additional tests when the reactor is started up.
The inspector will follow up on this item during the next inspection.
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13.
Accidental Isolation of the 1PCIS (Abnormal Cccurrence BFAO-7325) DPP representatives told the inspector that no additional leakage problems have occurred with the outer rupture diaphragm in the turbine discharge piping. They indicated that the esa of other rupture diaphragm designs had been considered, but TVA does not think that a change in design is necessary and have no plans for a change. The inspector stated that he had no further questions on this item.
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R0 Report No. 50-259/73-16 I-5 14.
Inoperative HPCI Level Ssitches (Abnormal Occurrences BFAO-7328 and 7332) The inspector confirmed I
with DPP representatives that the original 1/4 amp switches have been irstalled, each with an are suppressor around the switch load to prevent arcing. The inspector looked at the surveillance test record (SI-4.2.B-26) for these switches and confirmed that they had been satisfactorily tested. The inspector stated that he had no further questions on this item.
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Drywell Pressure Switch Setpoint Error (Abnormal Occurrence BFAO-7321) The inspector looked at the surveillance test records (SI-4.1.A-6) and confirmed that the accelerated surveillance testing had been successfully completed. The inspector stated that he had no further questions on this item.
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