IR 05000302/1990018
| ML20043G798 | |
| Person / Time | |
|---|---|
| Site: | Crystal River  |
| Issue date: | 06/01/1990 |
| From: | Belisle G, Taylor P NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20043G796 | List: |
| References | |
| 50-302-90-18, NUDOCS 9006210143 | |
| Download: ML20043G798 (5) | |
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UNITED ST ATES NUCLEAR REGULATORY COMMisslON
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f REGION il 101 MARIETTA STREET.N.W.
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ATL ANTA. GEORGI A 30323 k.....,/
Report No.:
50-302/90-18
. Licensee:
Florida Power Corporation
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3201 34th Street, South
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St. Petersburg, FL 33733
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. Docket No.:
50-302 License No.: DPR-72
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Facility Name: Crystal River 3 l
m-i Inspection Conducted: Apri1=30-May 4 and May 15-20, 1990
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Inspector:
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c - - vo P. A. Taylor /
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Date Signed
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Approved by: 7M. M. ZL f /Aug //,, v j - /- 46!
G. A. Belisle, Chief Date Signed
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Test Programs Section
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l Engineering Branch Division of Reactor Safety
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SUMMARY
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Scope:
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This routine, announced inspection was conducted in the areas ~ of
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pre-operational testing of the upgraded emergency diesel generators (EDGs).
Results:
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In the areas inspected, violations'or deviations were not identified.
A weakness was identified in not effectively translating test quantities
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identified in an NRR letter dated September 25, 1989, into plant implementing
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test procedures, MAP 88-01-12-01,- TP No I and TP No. 2 (paragraph 2c).
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V REPORT DETAILS 1.
Persons Contacted Licensee Employees
- G. Becker, Manager Site Nuclear Engineering
- R. Clarke, Nuclear Regulatory Specialist
- S. Johnson, Manager, Site Nuclear Services
- H. Koon, Assistant Nuclear Maintenance Superintendent
- W. Rossfeld, Manager, Nuclear Compliance
- J.-Terry, Supervisor, Site Nuclear Engineering Other licensee employees contacted during this inspection included craftsmen, engineers, operators, mechanics, technicians, and administra-tive personnel.
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NRC Resident Inspector
- P. Holmes-Ray
- Attended exit interview on May 4, 1990
- Attended exit interv'iew on May 20, 1990 2.
Pre-0perational Testing of the Upgrade EDGs a.
EDG Upgrade
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Three major modifications are being incorporated into the 3A and 3B EDGs during the current refueling outage.
The purposes of the modifications are to increase the electrical load capacity and the operating time for each EDG, Major changes include a new series air
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operating conditions, reduces exhaust smoke, and lowers exhaust, piston, and piston liner temperatures.
The rating will be increased to approximately 350 horse power per cylinder. To keep the lube oil temperatures within acceptable temperature limits, a modification to install new larger lube oil coolers is planned.
In addition, the replacement of diesel engine mechanical components includes new design pistons and piston liners, which will increase cylinder
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combustion capability.
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The inspector observed 3B EDG work activities associated with the replacement of mechanical components.
The inspector verified that working copies of the modification packages were available at the work area, Quality Control hold points were being observed, and tools (e.g. instrumentation, calipers, torque wrenches) were in a state of calibration.
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3A EDG Reliability Tests MAR 88-01-12-01, Test Procedure No. 2 dated April 24, 1990, was in progress when the inspector arrived on site. The purpose of the test was to demonstrate EDG reliability through a minimum of 30 valid start and load tests (2850-2900kw) without a failure to start and J
load.
The inspector witnessed test run nu:nbers 29 and 30 and verified that the test procedure being used was the latest revision.
In addition, the inspector observed the establishing of prerequisites
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and plant conditions prior to each test run.
These activities were well coordinated and carried out in a professional manner by the control room operators and the director of the test. A r ulew of the test results indicated that 30 valid start and load tests were achieved for the 3A EDG.
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Test Results Evaluation The licensee completed several tests on the 3A EDG in accordance with MAR 88-01-12-01. TP No.1 (dated April 6,1990), Functional Test for
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EDG Upgrade. This procedure provides for a carefully controlled test which is designed to start and run the diesel engine at minimum speed, then incrementally progress to rated speed (900 rpm) and load (2850kw). After selected tests, the EDG is shutdown and inspections
are made on the bearing and piston rings for overheating and wear.
In addition to these " break in" tests, NRR identified eight specific FDG tests (NRC letter dated September 25, 1989) which the staff concluded would constitute an acceptable test program. The inspector reviewed the licensee's implementing test procedures
. (MAR 88-01-12-01, TP No.1 and No. 2) for the incorporation of the NRR identified-EDG tests and identified the following discrepancies:
-l (1) MAR 88-01-12-01, TP No.1. Section 7.8, Hot Restart and Full Load Rejection Test
.1 NRR letter, Item 5, specifies that voltage be verified to meet (
requirements subsequent to the full load rejection.-
This parameter was not verified during the 3A EDG test.
The 3B EDG Full Load Reject Test has not been performed.
Appropriate changes need to be made to this test procedure to verify voltage that measurements are taken and are acceptable for both EDGs.
(2) MAR 88-01-12-01, TP No. 1, Section 7.8, Hot Restart Test NRR letter, item 7, requires that the diesel start and attain required voltage and frequency within limits and time specified
by Technical Specification (i.e. less than or equal to 10-l seconds).
The test director record the time as 8.4 seconds during the 3A EDG test in the test log.
Prior to testing the
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3B EDG, procedure changes need to be made to add the
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Technical Specification limits and times as acceptance criteria i
and provide specific test steps to ensure that this data in recorded and evaluated, j
i (3) MAR 88-01-12-01, TP No. 2, Section 7.2, Single Load Reject Test q
NRR letter, Item 4, specifies that voltage and frcquency be verified to meet requirements subsequent to the single load
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reject test.
Appropriate changes need to be made to this test procedure to verify that voltage and frequency measurement are taken. This test has not been performed yet on either EDG, The licensee stated at the exit interview that appropriate changes would be made and the full load rejection test repeated for the 3A EDG.
Test procedure changes. would also be made for the other - identified
discrepancies prior to conducting the tests, d.
3B EDG Pre-Operational Tests
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On May 16, 1990, the licensee started a series of pre-operational tests for the 3B EDG.
The inspector reviewed MAR 88-02-12-01, TP4 and TP5 which had been issued to accomplish the pre-operational tests.
It was noted that these test procedures are similar to the test procedures previously reviewed for the 3A EDG.
Items identified in parsgraph 2c as deficiencies have been appropriately addressed in these test procedures for the 38 EDG.
In addition the licensee has issued MAR 88-01-12-01 TP3, Full Load Rejection Test 3A EDG, which will be used to conduct the full load rejection test.
Voltage conditions will be measured during
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the transient to ensure voltage requirements are met.
The inspector witnessed portions of the following tests (MAR 88-01-12-01 TP4) which are designed to ensure that modifications.
made to upgrade the EDGs have been correctly installed, the diesel engine performance at the new continuous rating (2850 kw) is satisfactory, and the diesel generator exhibits reliability:
An initial five minute minimum speed run from a slow start with
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no load, followed by a bearing inspection for overheating after the run.
A no load 15 minute run at 500 rpm, followed by a leak test of
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the engine exhaust, oil and water systems and a bearing inspection after the run.
The engine was slow started and speed was increased to 900 rpm
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(Normal Rated Speed) in 100 rpm increments with a piston ring and bearing inspection after the run.
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Progressive " Break In" runs were observed, starting at 25% of rated
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load increasing to 75%.
A piston ring and cylinder lining
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inspection was conducted after the 75% ru.
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Fast Start Test.
The EDG was started from ambient temperature
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i and verification that voltage and frequency were within limits
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and time as per Technical Specifications requirements.
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Endurance and Margin Test. The EDG was loaded at 2800 to 2850kw i
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for a minimum of 22 hours2.546296e-4 days <br />0.00611 hours <br />3.637566e-5 weeks <br />8.371e-6 months <br /> followed immediately by a minimum of 2
hours at 3135 - 3185kw.
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Hot Restart and Full Load Rejection.
This test was started
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immediately following the shutdown from the endurance and margin
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test.. The EDG was loaded to 3100 - 3150kw then-the EDG breaker opened. During the transient, voltage measurements were recorded
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p and verification that the diesel engine did not trip on overspeed.
These test activities were observed to verify that'they were conducted in accordance with the test procedure requirements, test data was being properly recorded and a preliminery evaluation of test results was being made. Test results indicate satisfactory 3B EDG operation,-
however, three diesel parameters were noted to be reading higher than expected during the 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> endurance and margin test.
Scavenge air'
temperature averaged approximate 160 F (expected 105-150'F), Jacket water temperature across the engine averaged approximately 31 F (expected less than 10*F) and jacket water outlet temperature.
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averagedapproximately189'Ffromthe17thhour(expected 145-1859.i.
The licensee is evaluating these parameters with vendor representa-a tives (Colt-Fairbanks/ Morris).
Within the areas inspected, violations and deviations were not identified.
3.
Ex'it Interview The inspection scope and results were summarized-on May 4'and May 20, 1990,x
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with those persons indicated in paragraph 1.
The inspector described the
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- areas inspected and discussed in detail the inspection results listed below.
Proprietary information -is not contained in' this report.,
Dissenting coments were not received from the licensee, a.
Correct MAR 88-01-12-01, TP No. 1 and TP No. 2 to include those test quantities identified in NRR letter dated September 25, 1989, for the 3A and 3B EDGs (paragraph 2c).
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Repeat the Full Load Rejection Test for the 3A EDG.
Include in the test verification that voltage requirements are met and the diesel will not
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trip on overspeed jparagraph 2c).