IR 05000412/1986004

Insp Rept 50-412/86-04 on 860201-28.No Violations or Significant Safety Concerns Identified.Major Areas Inspected:Licensee Actions on Previous Insp Findings & Preoperational Program Implementation

ML20154N371
Person / Time
Site:	Beaver Valley
Issue date:	03/07/1986
From:	Lester Tripp NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20154N355	List: IR 05000412/1986004 ML20154N352
References
50-412-86-04, 50-412-86-4, NUDOCS 8603170304
Download: ML20154N371 (8)

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U.S. NUCLEAR REGULATORY COMISSION -

REGION I

Report N /86-04 Docket N License N CPPR-105 Licensee: Duquesne Light Company Nuclear Construction Division P. O. Box 328 Shippingport, PA 15077 Facility Name: Beaver Valley Power Station, Unit 2 Dates: February 1 - 28, 1986 Inspectors: W. M. Troskoski, Senior Resident Inspector L. J. Prividy, Resident Inspector Approved by: d .h. *h8 3/7/g[r L. E. Tripp, Chief, Reactor Projects Section 3A ' D' ate Inspection Summary: Inspection No. 50-412/86-04 on February 1 - 28, 198 Areas Inspected: Routine inspections by the resident inspectors (62 hours7.175926e-4 days <br />0.0172 hours <br />1.025132e-4 weeks <br />2.3591e-5 months <br />) of licensee actions on previous inspection findings, preoperational program implemen-tation, emergency diesel generator qualification and proof testing, review of re-circulation spray system and quench spray system preoperational tests, and turbine driven auxiliary feed pump tes Results: No violations or significant safety concerns were identifie kh0 D 2

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DETAILS Persons Contacted R. Coupland, Director, Site Quality Control C. E. Ewing, Manager, Quality Assurance T. P. Noonan,' Station Superintendent R. J. Swiderski, Startup Manager D. Williams, Chairman, Joint Test Group The inspector also met with other licensee and contractor personnel during the course of the inspectio . Pro.iect Status Summary Construction activities are currently estimated to be 92.7% complete, with 260 of 450 subsystems turned over for flushing and proof-testing. For soft-ware, 49 out of 123 preoperational (PO) and initial startup tests (IST) have been issued. The remainder are in various phases of developmen Approximate dates for the major project milestones, as currently estimated by the licensee are as follows:

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Reactor Coolant System Cold Hydrostatic Test March 17, 1986

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Integrated Hot Functional Test October 20, 1986

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Fuel Receipt September 1, 1986

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Loss of Power Test February 2, 1987

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Integrated Leak Rate Test February 23, 1987

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Fuel Load May 1, 1987

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Initial Startup May 16, 1987

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Commercial Operation August 30, 1987 Major activities planned for next month include finishing the CVCS and RCS flushes, RCS cold hydrostatic test, shoot peening steam generator tube sheets for stress relief, and initial turnover of the Low Head Safety Injection Sys-te The remaining ESF systems are not scheduled until after the RCS hydr . Licensee Action on Previous Inspection Findings No open items were reviewed during the course of this inspectio . Emergency Diesel Generator Testing Purpose Vendor qualification test records and construction proof test procedures were reviewed to ensure technical adequacy and consistency with Regula-tory requirements, guidance and station commitments. Portions of the proof tests were witnessed to verify that the test was conducted in ac-

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cordance with approved procedures, that those procedures were available to personnel conducting the test, and test data was collected and re-corded in an approved manne References

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BVPS-2 FSAR, Section 8.3, Onsite Power Systems

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BVPS-2 FSAR, Section 14.2.12.54, 4KV Station Service

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Regulatory Guide 1.9, Selection, Design and Qualification of Diesel Generator Units Used As Onsite Electrical Power Systems at Nuclear Power Plants

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Regulatory Guide 1.108, Periodic Testing of Diesel Generator Units

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IEEE Standard 387-1977, Criteria for Diesel Generator Units Applied as Standby Power Supplies

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IEEE Standard 308-1974, Criteria for Class 1E Power Systems c. Prototype Qualification Testing Though the diesel generator units supplied for BVPS-2 were manufactured by Colt Industries, Fairbank-Morse Engine Division, and are similar to those previously qualified by Alabama Power Company, qualification by similarity was not pursued. Verification of suitability of the diesel generator units was made by testing to meet the requirements for engine qualification and load acceptance tests of IEEE Standard 387-1977 and Regulatory Guide 1.108. The inspector reviewed the engineering report dated July 26, 1978 by Colt Industries detailing the 300 start and load acceptance qualification tests on the second diesel generator (S/N 2061478) conducted during June, 1978. Of those, 270 starts were per-formed from warm standby temperature with one failure and 30 starts were from normal equilibrium temperatures with no failures. The failed com-ponent was a rocker arm mechanism of cylinder number 1 (during start number 147). After the immediate start, a single step load of greater than 50% of the generator nameplate (4662 kW) continuous kW rating was applied, with frequency recovery to 98% within four seconds with voltage remaining essentially the same for each test. The diesel accepted loads within 7 to 8 seconds. When loaded in accordance with the loading se-quence, voltage was not less than 75% of nominal and frequency was not less than 95% nominal for motor loads up to 1670 HP. The largest motor currently on the diesel generator loading sequence at Beaver Valley, is 1250 H To insure load carrying capability, tests verified that the temperature of jacket coolant out of the engine after obtaining equilibrium did not exceed 152.7 F, the temperature of the lube oil out of the engine did not exceed 160 F and the temperature rise of jacket water through the engine did not exceed 15 F.

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Overspeed tests are required to verify that the protective trip function prevents an engine speed from exceeding 576 rp The 115% load test re-quires the diesel generator to carry 6784 bhp without exceeding equilib-rium temperature of 160 F lube oil and 152.7 F jacket water. These tests will be rerun on site as part of the preoperational test progra Motor starting tests were conducted to verify the diesel generator is capable of accepting the resistive and motor loads without experiencing instability resulting from generator voltage collapse or significant evidence of a failure of the voltage to recover and to demonstrate that there is sufficient torque available to prevent engine stall and to per-mit engine speed to recover. By using the 1670 HP motor which is greater than the largest single step load of 1250 HP, the margin test represents a 35% margin above the most severe single step load within the design sequence. This meets the requirements of IEEE Standard 387-1977,(6.3.3)

which requires only a 10% load test margi Based on the above, the inspector concluded that the BV-2 diesel genera-tors meet the qualification requirements, d. Test Conduct - Construction Proof Testing During February 19 - 21, and 24 - 28, 1986, the inspector observed the No.1 diesel generator test run under Construction Proof Test 2T-NNS-368-2.23, Initial Loading of Emergency Diesel Generator. This test starts the EDG and brings it up to rated speed on mechanical governor, verifies generator parameters after the generator field is flashed, places the electrical governor in service, synchronizes the EDG to the bus with the output breaker closed, performs a cut-in verification of the protective relays with power at a minimum, and loads the generator in stages monitoring various parameters. Throughout the test, admini-strative controls for test conduct to assure personnel and equipment safety were implemente The proof test identified several instances where instrument wires were crossed. Examples include the governor, control room meters and breaker cts. Discussions with test engineers indicated that in each case, the wires were installed per the installation drawing, which was in erro Engineering and Design Coordination Reports were issued to correct the field wiring and drawing, and QC was present to verify the work. Test program procedures for correcting installation errors appear to be ef-fectively implemente During a load test on February 28, 1986, the diesel momentarily oversped to 110%. After dropping back, test personnel noted an imbalance as the Number 5 cylinder fuel injector pump failed full open. The test was terminated and the pump was replaced with a spare. Discussions with the vendor's representative indicated that this type of failure was not ex-pected to result in exceeding the 1200 F rated cylinder temperature as the excess fuel is not burnt. Determination of the fuel injector pump's failure cause is IFI (85-04-01).

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5 Preventive Maintenance, Surveillance and Test Programs for the EDG The inspector discussed preventive maintenance plans for the EDG with the Maintenance Supervisor. The 18-month frequency electrical and mechanical procedures have already been developed in the ilaintenance Surveillance Procedure (MSP) format that is successfully used at Unit 1. The inspector noted that these 18-month MSPs did not appear to be sufficient to support all vendor recommended inspection and testing at extended frequencies (usually 3, 6, and 9 year intervals, plus specific items dependent on the amount of hours on the engine). This concern is similar to Unresolved Item 334/85-22-06, that BV-1 is working on so that the EDG procedures comply with vendor recommendations to ensure a high degree of reliabilit The Maintenance Supervisor stated that the BV-2 EDG procedures would also receive such a review. This will be tracked as Unresolved Item (86-04-02).

Discussions with the Operations Supervisor indicated that temporary logs were being developed as turnover progressed on plant systems. The draft logs for the final as-built EDG have been developed, but are still un-approve Operational surveillance tests are under development. However, the BV-2 Technical Specification review by NRR has just begun, and final approval is not expected for some time. As the Technical Specifications contain the approved surveillance test acceptance criteria, the final OST issue cannot yet be made, Potentially Generic Problems Experiented at other Facilitie (1) Colt submittee a 10 CFR Part 21 Report dated February 4, 1986, con-cerning tia EDG model used at BV-2. The vendor determined that the diesel generator air start system which actuates the governor rack boost is not vented from the rack boost promptly after the start signal termination, causing it to fight the governor and create a potential overspeed condition. The inspector discussed this with the vendor's representative and the Senior Test Engineer. Though they were aware of the problem, the station has not yet made its engineering evaluation. This is Unresolved Item (86-04-03).

(2) A generator was severely damaged at another facility when its out-board metal screen inspection plate was sucked into it during a monthly surveillance test. Discussions with the vendor's represen-tative at BV-2 and communications with the vendor's representative at that facility indicated that the generator screen design was different between the two units, and the metal screen had not been properly reinstalled at that facilit However, the inspector noted that many of the bolts that hold sections of the Unit 2 generator screen in place had been stripped and were missing, resulting in vibration when the diesel is running. Followup to insure that these bolts are replaced in a timely manner and are of a correct size, is IFI (86-04-04).

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(3) Some nuts which are used to hold the diesel generator engine con-necting rod and rod bearing caps in place were reported to be manu-factured incorrectly at another facility. These nuts have faces which are not perpendicular to the thread pitch line. The result is that the fitup to the mating surface (the connecting rod cap),

is not parallel, and could result in stress in excess of desig Though these specific nuts were received after April 9,1984, and were not part of the initial engine installation, a review to de-termine whether or not they are site spare parts is Inspector Follow Item (86-04-05).

(4) PN0-I-86-19 provided information on a Fairbanks Morse EDG aluminum scavenging air blower failure that occurred after 51 hours5.902778e-4 days <br />0.0142 hours <br />8.43254e-5 weeks <br />1.94055e-5 months <br /> of con-tinuous operation at low-load. Though the BV-2 EDGs are 12 cylinder, 45 degree V engines, that do not use a scavenging air blower, dis-cussions with the vendor's representative indicated that there are definite limits for running at no-load or low-load conditions; the EDG should be run at one-half load for one hour of every 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> at low-load. Through discussions with test personnel and observa-tion of ongoing proof tests, the inspector verified that this prac-tice was being implemented. Most of the testing to date has con-sisted of loading the EDG to specified load plateaus while measuring various parameter The inspector had no further concern EDG Preoperational (PO) Test Development Of the four P0s referenced in Section 14.2 of the FSAR, one was scheduled for review by the JTG on February 25, 1986. The other three are under-going the second draft review by the A-E. The first of these P0.c h not scheduled until aboet one month after the RCS cold hydrostatic tes . Preoperational Test Procedure Review - Recirculation Spray System and Quench Spray System Purpose The Containment Depressurization System is (i. engineered safety feature (ESF)

consisting of the Quanch Spray System, Chemical Addition Subsystem and Re-circulation Spray System. BV-2 has developed five preoperational tests (PO)

that have been reviewed and approved by the JTG. The inspector reviewed PO-2.13.01, Recirculation Spray System Pumps, and P0-213-02, Quench Spray System Pumps, to verify technical adequacy and ensure consistency with Regulatory requirements, guidance and licensee commitment References FSAR Section 14.12.15.1, RSS Pumps and Control Tests FSAR Section 14.12.15.2, Quench Spray Pumps and Control Tests FSAR Section 6, ESF J

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Findings The inspector determined that P0-2.13.01 provided an adequate test of the alarm and annunciation system, measured pump operating parameters (discharge pressure flow rate), verified auto-start and control logic (CIB) and measured valve stroke times. The acceptance criteria were as specified in Test Speci-fication 2-TSP-CSS-13A.A. The inspector noted that the RSS startup delay time was specified as 628 seconds as opposed to the 215 second value recorded in the Unit 2 Operating Manual Chapter and used by Unit 1. In discussing this with the cognizant test engineer, the inspector was informed that this item was recalculated to provide the RSS pump performance curve with an improved net positive suction hea Additionally, the information was updated in Amendment No. 5 dated February, 198 As part of the containment sump hydraulic study, the A-E noted that during the main steam line break, adequate water level could not be assured and operator action would be required to stop the RSS pump before damage occur These actions would have to include a reset of the CIB and manual stopping of the pump Consequently, the emergency operating procedures would have to contain the necessary steps. The inspector discussed this item with the F0P Procedure writer and verified that this information had been channeled to him. The inspector was informed that the BV Unit 2 E0Ps were developed from the Westinghouse Owner's Group and modified for the plant specific item The first issue is due during the week of March 3, 1986, with the first tabletop validation scheduled for April,198 RSS test specifications were consistent with the assumptions in the various FSAR sections. The inspector determined that this preoperational test would adequately demonstrate the recirculation spray system pump operability and control logic assumed in the safety analysi Review cf P0-2.13.02 likewise verified that the various operating character-istics and control logic were tested as specified in the FSAR. However, the inspector noted that the specific test specifications for this system had not yet been specified in the reference section (IX) of the test. Additionally, some parameters such as the pump low flow alarm setpoint and low flow alarm delay have not yet been provided. Therefore, further review of the test specifications and the test procedure acceptance criteria is Inspector Follow Item (86-04-06).

6. Turbine Driven Auxiliary Feed Pump Test The possibility of a water hammer developing in the steam piping to the auxiliary feed pump turbine due p. imarily to the long run of the 3" piping from the Main Steam and Cable Vault Areas to the basement of the Safeguards Building was initially identified in Inspection Report 412/85-26. The in-spector subsequently learned that the water hammer should not be a problem since drip pots were included in the 3" main steam piping to collect and dis-charge condensate that may form. The inspector was advised that detailed operating procedures had not yet been developed concerning the operation and alignment of these drip pots.

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Discussions with Testing personnel responsible for preparing test procedure P0-2.248.02, Turbine Driven Auxiliary Feed Pump, indicated that the test cur-rently had no provisions for monitoring the piping for water hammer during the test. The inspector noted that such monitoring should be provided to enable proper evaluation of the performance of the drip pots in the 3" main steam line. Test personnel acknowledged that concern and committed to carry it as an open item on the SVG Software Deficiency Tracking Report, to be re-viewed by the JTG prior to test issuance. This is Inspector Follow Item (86-04-07).

7. Exit Interview A meeting was held with senior DLC startup testing personnel on March 3, 1986, to discuss the inspection scope and findings.