IR 05000348/1987008

Insp Repts 50-348/87-08 & 50-364/87-08 on 870311-0410.No Violations or Deviations Noted.Major Areas Inspected:Monthly Surveillance & Maint Observations,Operational Safety Verification,Lers & Maint Program Implementation

ML20209G155
Person / Time
Site:	Farley
Issue date:	04/17/1987
From:	Brian Bonser, Bradford W, Dance H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20209G118	List: IR 05000348/1987008 ML20209G112
References
50-348-87-08, 50-348-87-8, 50-364-87-08, 50-364-87-8, NUDOCS 8704300489
Download: ML20209G155 (10)

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p f.t ro UNITED STATES

/ 'o NUCLEAR REGULATORY COMMISSION

[~ p REGION 11 g j 101 MARIETTA STREET, * e ATLANTA, GEORGI A 30323

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Report Nos.: 50-348/87-08 and 50-364/87-08 Licensee: Alabama Power Company 600 North 18th Street Birmingham, AL 35291 Docket Nos.: 50-348 and 50-364 License Nos.: NPF-2 and NPF-8 Facility name: Farley 1 and 2 Inspection Conducted: March 11 - April 10, 1987 Inspection at Farley site near Doth n, Alabama Inspectors: b E H. Bradf kd

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Date!gned'l} !fY B. onsor s Datd Sigrfed Approved by: MW /7 [7 H'. C. Dance, Se'ction Chief Date 'Sidn#d Division of Reactor Projects

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SUMMARY Scope: This routine, onsite inspection entailed, monthly surveillance observation, monthly maintenance observation, operational safety verification, licensee event reports, and maintenance program implementatio Results: Within the areas inspected there were no violations or deviations identifie PDR ADOCK 0500 G

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i REPORT DETAILS Licensee Employees Contacted:

J. D. Woodard, General Plant Manager  !

D. N. Morey, Assistant General Plant Manager l W. D. Shipman, Assistant General Plant Manager R. D. Hill, Operations Manager C. D. Nesbitt, Technical Manager R. G. Berryhill, Systems Performance and Planning Manager L. A. Ward, Maintenance Manager L. W. Enfinger, Administrative Manager B. Moore, Operations Supervisor J. E. Odom,. Operations Unit Supervisor B. W. Vanlandingham, Operations Unit Supervisor T. H. Esteve, Planning Supervisor J. B. Hudspeth, Document Control Supervisor L. K. Jones, Material Supervisor R. H. Marlow, Technical Supervisor L. M. Stinson, Plant Modification Manager J. K. 0sterholtz, Supervisor, Safety Audit Engineering Review Other licensee employees contacted included technicians, operations personnel, maintenance and I&C personnel, security force members, and office personne . Exit Interview The inspection scope and findings were summarized during management interviews throughout the report period and on April 10, 1987, with the general plant manager and selected members of his staff. The inspection findings were discussed in detail. The licensee did not identify as proprietary any material reviewed by the inspector during this inspectio . Licensee Action on Previous Enforcement Matters (92702)

(Closed) Violation 364/85-43-01, Failure to follow new fuel receipt and inspection procedure. Alabama Power Company's letter of response dated February 6, 1986 details the licensee's corrective action. The inspectors have reviewed this corrective action and verified that instructions have been added to the fuel handling procedure which requires certain functions to be completed, verified and initialed prior to the fuel assembly being upended to the vertical positio (Closed) Violation 364/85-44-01 Failure to follow approved Administrative Procedures which requires the Instrument and Control Foreman to review all I & C surveillance tests performed on his shift for completeness and accuracy and to so indicate by signing and dating the procedure. Alabama

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Power Company letter of response dated April 1,1986 details the licensee's corrective action. The inspectors have reviewed this corrective action and have no further question (Closed) Violation 364/86-15-01 Violation of Technical Specification which requires that the Auxiliary feedwater flow paths be verified by flow tests prior to entry _into Mode 2. Alabama Power Company letter of response dated September 11, 1986 details the licensee's corrective action. The inspectors have reviewed this corrective action and have no further question . Monthly Surveillance Observation (61726)

The inspectors observed and reviewed Technical Specification required surveillance testing and verified that testing was performed in accordance with adequate procedures; that test instrumentation was calibrated; that limiting conditions were met; that test results met acceptance criteria and were reviewed by personnel other than the individual directing the test; that any deficiencies identified during the testing were properly reviewed and resolved by appropriate management personnel; and that personnel conducting the tests were qualified. The inspector witnessed / reviewed portions of the following test activities:

IMP-209.26 - MDAFW pump suction pressure calibratio FNP-0-MP28.190 - Transformer Combustible Gas Tes STP-3 Reactor Trip Breaker Operability Tes STP-1 RHR Valve IS STP-1 RHR System Check Valve IS STP- RCS Leakag i

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STP-2 "A" Train Control Room Ventilatio STP-2 Service Water Pumps 1A, B, and C Quarterly IS STP-61 Inaccessible Snubbers Visual Inspection (Procedure Review only).

1-U0P- Shutdown of unit from minimum load and Hot Shutdow %

No violations or deviations were identifie '

5. Monthly Maintenance Observation (62703)

Station maintenance activities of safety-related systems and components were observed / reviewed to ascertain that they were conducted in accordance with approved procedures, regulatory guides, industry codes and standards, and were in conformance with Technical specification The following items were considered during the review: limiting conditions for operations were met while components or systems were removed from service; approvals were obtained prior to initiating the work; activities were accomplished using approved procedures and were

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inspected as applicable; functional testing and/or calibrations were performed prior to returning components or systems to service; quality control records were maintained; activities were accomplished by qualified personnel; parts and materials were properly certified; radiological controls were implemented; and fire prevention controls were implemente Work requests were reviewed to determine the status of outstanding jobs to assure that priority was assigned to safety-related equipment maintenance which may affect system performance. The following maintenance activities were observed / reviewed:

Diesel Generator 1-2A Maintenance Outag Unit 2 Spray Additive Recirculation Pump (MWR-143616).

MDAFP to "C" steam generator check valve (MWR-157612).

Unit 1 - Steam Generator 1C Manwa Unit 1 "C" RTD manifold valve leak repai Unit 1 - S/G Blowdown valve leak repai No violations or deviations were identifie . Operational Safety Verification (71707)

The inspectors observed control room operations, reviewed applicable logs and conducted discussions with control room operators during the report period. The inspectors verified the operability of selected emergency systems, reviewed tagout records, and verified proper return to service of affected component Tours of the auxiliary building, diesel building, turbine building and service water structure were conducted to observe plant equipment conditions, including fluid leaks and excessive vibrations. The inspector verified compliance with selected Limiting Conditions for Operations (LCO) and results of selected surveillance test The verifications were accomplished by direct observation of monitoring instrumentation, valve positions, switch positions, accessible hydraulic snubbers, and review of completed logs, records, and chemistry results. The licensee's compliance with LC0 action statements were reviewed as events occurre The inspectors routinely attended meetings with certain licensee management and observed various shift turnovers between shift supervisor, shift foremen and licensed operator These meetings and discussions provided a daily status of plant operations, maintenance, and testing activities in progress, as well as discussions of significant problem The inspector verified by observation and interviews with security force members that measures taken to assure the physical protection of the facility met current requirement Areas inspected included the organization of the security force; the establishment and maintenance of gates, doors, and isolation zones; that access control and badging were proper; and procedures were followe ..- -. - - _

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During the inspection period the licensee noted a slight increase in Unit I reactor coolant system (RCS) unidentified leakage. The normal unidentified leakage is between 0.1 and 0.2 GP However, containment radiation element R-11 showed an increase in containment activity, plus a slight increase in level in the containment building sump prompted the licensee to decrease power to about 30% and to make a containment entry to identify the source of the leakage. The leakage was found to be from a body to bonnet leak on the RTD manifold isolation valve on "C" RCS loo Small leaks were.also found on the normal and alternate charging valves

and "C" steam generator secondary side blowdown valve. The licensee shut down Unit 1 on April 6,1987, for a ten day maintenance outage. During

. the outage all leaks were repaired and other maintenance activities were complete The licensee had a Combustion Engineering (CE) representative on site to inspect the reactor vessel level monitoring system and make any repairs and adjustment During this inspection he found a minute leak on a

"Greyloc" flange on the reactor vessel head. The leak was identified by a small amount of boric acid building up, less than 1 ounce. The "Greyloc" flange was repaired by installing new seal The repair on the RTD manifold valve and the "Greyloc" flange will be tested when the RCS reaches operating pressur Within the areas inspected no violations or deviations were identifie . Licensee Event Reports (92700)

The following Licensee Event Reports (LERs) were reviewed for potential generic problems to determine trends, to determine whether information included in the report meets the NRC reporting requirements and to consider whether the corrective action discussed in the report appears appropriate. Licensee action, with respect to selected reports, were reviewed to verify that the event had been reviewed and evaluated by the licensee as required by the Technical Specification; that corrective action was taken by the licensee; and that safety limits, limiting safety setting and LCOs were not exceede The inspector examined selected incidents reports, logs and records and interviewed selected personne The following reports are considered closed:

Unit 1 LER-87-01 - Technical Specification Action Statements not met when Radiation Monitor R-11 was inoperabl LER-87-02 - Unit manually tripped due to a leak on air supply line to MSI .. - - _ - - _ - . - - . _ - . - - . .

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LER-87-03 - Reactor trip due to tripping of both steam Generator Feed Pump LER-87-04 - High flux rate reactor trip caused by 1A Inverter failing while NI-42 was being teste LER-87-05 - Technical Specification 3.0.3 entered due to inoperable Containment Isolation Valve Unit 2 LER-87-01 - Reactor trip due to a spike occurring on channel one of Over-Temperature-Delta-T while channel three was in tes No violations or deviations were identifie . Maintenance Program Implementation (62700)

The inspector reviewed the Farley Nuclear Plant maintenance program implementation to determine whether the maintenance program is being implemented in accordance with regulatory requirements, to determine the effectiveness of the maintenance program on important plant equipment and to determine the ability of the maintenance staff to conduct an effective

program.

I Maintenance is observed by the resident inspectors as part of the monthly inspection program. This inspection looked more closely at records of selected maintenance activities. The maintenance activities selected covered four general areas:

. Safety related (SR) equipment failure (s) leading to a plant shutdown

. Non-SR equipment failure (s) leading to a plant shutdown

. Equipment failure leading to a reduced capability of a SR system

. Recurring SR equipment failure The maintenance areas selected for inspection were:

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Failure of General Electric containment electrical penetrations

. Main turbine interface valve problems

. Inverter failures

. Recurring charging pump problems

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Records associated with the maintenance activities were reviewed to determine whether the cause of the failure was evaluated and adequate corrective action taken, whether the procedures specified in the maintenance package were adequate for the scope of the maintenance performed, whether the vendor technical manuals for the equipment under repair were controlled and kept current, whether vendor maintenance recommendations, if utilized, were correctly translated into maintenance and whether periodic surveillance testing associated with the selected failed equipment provided any indication of imminent failur Farley Nuclear Plant Unit 1 has suffered failures in General Electric containment electrical penetration modules leading to a reactor tri Plant maintenance records were reviewed and maintenance was observed in an on going basis during the course of the failures and recovery and during the replacement of the GE modules with Conax module Selected maintenance activities on the Unit 1 and 2 turbine interface valves were reviewed. Failures have recently led to one reactor trip and one power reduction on Unit Maintenance work requests reviewed were:

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MWR 147921 -

Interface valve packing Leak MWR 135276 -

Interface valve ruptured diaphram MWR 134525 - Changout of Unit 1 and 2 interface valves actuator MWR 132172 - 011 leak on top of interface valve actuator Selected maintenance activities related to problems with the centrifugal charging pumps gear oil coolers and high vibration were reviewe Maintenance work requests reviewed were:

MWR 11882, 11882A 11882B, 11882C - IB Charging pump reduction gear oil cooler running hot MWR 91446 - Rod out 1C Charging pump oil coolers MWR 91445 - Rod out 1B Charging pump oil coolers MWR 91444 - Rod out 1A Charging pump oil coolers MWR 102632, 102632A - High lube oil temperature alarm on 1C Charging Pump MWR 120870 - 1A Charging pump speed charger oil temperature high MWR 132986 - 1A Charging pump oil leak MWR 128948 - 18 Charging pump-rod out oil cooler MWR 136371 - IC Charging pump-rod out oil cooler MWR 140114 - 1B Charging pump-clean and inspect oil cooler MWR 147970 - 1B Charging pump high reduction gear temperature MWR 145222 - 1A Charging pump-inspection bearing oil heat exchanger MWR 145221 - 1A Charging pump-inspect gear oil cooler MWR 131526 - 1A Charging pump-vibration in alert range MWR 132960 - 1A Charging pump-vibration out of specification MWR 154844 - 18 Charging pump-vibrations in required action range MWR 147924 - 1A Charging pump-change out rotating assembly

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Selected maintenance activities on the SR -inverters were reviewed.

. Maintenance work requests reviewed were:

MWR 116685 - Unit trip on 2B inverter fault MWR 105971 - IC Inverter Trip MWR 100475 - Inspect 28 inverter MWR 100477 - Inspect 2D inverter The records associated with the maintenance activities listed above and other completed maintenance was also reviewed for compliance with Farley Nuclear Plant administrative procedures. Several maintenance procedures and technical manuals used to conduct the work items selected above were reviewed. The procedures were reviewed for conformance to the licensee's administrative requirements, for sufficient detail, for inspection and hold points being identified in the procedure and identification of appropriate

, reference material. The referenced technical manuals were reviewed for l adequacy and that they were being controlled. The documents reviewed were:

FNP-0-MP- Maintenance of Charging /High Head Safety Injection

Pump FNP-0-MP- Vibration measurements for Charging Pump and Moto FNP-0-MP-51 - Inservice testing of 5KVA and 7.5KVA Inverters.

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FNP-0-MP-51.1 - Outage voltage tuning of SKVA and 7.5KVA Westinghouse Inverter U-277513C - Pacific Pumps 2's RL, Type IJ Safety Pump U-210676C - Instrument Power Supply Inverters Instruction Book SKV Completed instrument calibration procedures and associated maintenance for three instruments was reviewed. The instrument calibration procedures selected were:

. FNP-1-STP-20 AFW to S/G 1A Flow Loop 3229A FNP-1-STP-201.29 - Pressurizer Level Calibration LT-459Z FNP-1-IMP-209.27 - MDAFW Pump Suction Pressure Loop

A review of the preventive maintenance (PM) program was performed. The

review included reviewing the Instrumentation and controls PM program, a review of the plant lubrication program and a review of FNP-0-GMP-1

" Preventive Maintenance Procedure" and FNP-0-AP-28 " Plant Lubrication Program". The review verified schedules were available and being used, a compilation of late and incompleted PM activities is available, a means to make input into the PM program is established, and PM procedures are

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available and sufficiently detaile The maintenance training program was reviewed for initial qualification and training and periodic retraining. Procedures reviewed were:

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FNP-0-TCP-6.0 -- Training system development FNP-0-TCP- INP0 accreditation of training programs FNP-0-TCP-16.0 - Technical task analysis FNP-0-TCP-17.11-- Maintenance advanced program administration Curriculum Guide for Maintenance Group No violations or deviations were identified.

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FNP-0-TCP- Training system development FNP-0-TCP- INP0 accreditation of training programs FNP-0-TCP-1 Technical task analysis FNP-0-TCP-17.11- Maintenance advanced program administration Curriculum Guide for Maintenance Group 'No violations or deviations were identified.

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