IR 05000412/1986038

Insp Rept 50-412/86-38 on 861103-07.No Violations Noted. Major Areas Inspected:Preoperational Test Program,Including Review of Joint Test Group Approved Procedures & Witnessing of Preoperational Tests

ML20215C843
Person / Time
Site:	Beaver Valley
Issue date:	12/02/1986
From:	Florek D, Van Kessel H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20215C836	List: IR 05000412/1986038 ML20215C832
References
50-412-86-38, NUDOCS 8612150457
Download: ML20215C843 (10)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

Report N /86-38 Docket N License N CPPR-105 Category B Licensee: Duquesne Light Company Post Office Box 4 Shippingport, Pennsylvania 15077 Facility Name: Beaver Valley Power Station, Unit No. 2

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Inspcction At: Shippingport, Pennsylvania #

l Inspection Conducted: November, 3-7,1986j

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Inspectors: bh/ \ ll-26-8b ~

H. F. van' Kessel, Feactor Engineer date l Approved by: >

_ J. Florek, Chief I qate f Test Program Section. OB, DRS '

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Inspection Summary: Inspection on November 3-7,1"86 (Inspection Number 50-412/86-38). I l

Areas Inspected: Routine unannounced inspection of the preoperational test f program, including the review of Joint Test Group (JTG) approved prccedures for preoperational tests, the witnessing of preoperational tests, the review of Phase-1 test results, the review of activities in the the QA interface, and >

the review of unresolved items identified by the inspector in previous I inspections. The new test facility (cn-site) for the MSIV operators was visited by the inspector. The operating history of the Emergency Diesel Generators (EDGs) was reviewed. The EDGs were inspected in sit l Results: No violations were identifie NOTE: For acronyms not defined refer to NUREG 0544, " Handbook of Acronyms and Initialisms .

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DETAILS Persons Contacted Duquesne Light Company (DLC)

• J. M. Arthur, Chairman

• R. C. Callaway, Test Supervisor Phase-2 N. J. Dougherty, Director Systems Testing E. Freeman, Test Engineer, Phase-1 and 2

• J. P. Godleski, Senior Test Engineer

• J. C. Folkens, Senior QA Specialist N. Harlow, Test Director, NSSS J. Maloney, Test Engineer F. Michael, Test Coordinator, Phase-2 J. Miller, Senior QA Specialist

• T. F. Noonan, Superintendent Operations & Maintenance

• L. M. Rabenau, Compliance Engineer

• J. Swiderski, Startup Manager J. N. Walsh, Test Engineer NSSS

• C. Warren, QA Surveillance Specialist

• G. Williams, Software Dev. Supervisor L. P. Williams, Test Director, Phase-1 Stone and Webster Engineering and Construction, In S. Leavitt, Test Specialist A. Sullivan, Test Coordinator U.S. Nuclear Regulatory Commission J. Beall, Senior Resident Inspector - Beaver Valley-2

• Denotes those present at exit interview on November 7, 198 . Licensee Actions on Previous Inspection Findings (Closed) Unresolved Item 412/86-32-01, " Discrepancies in test program for HFT as shown in P0 2.06.08" Scope

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In the review of the Hot Functional Test (HFT) procedure three items were identified (see Inspection Report No. 50-412/86-32).

Discussion With reference to Item 1, the flow rate of seal water to, and leak off from, each RCP will be measured and adjusted in preoperational test procedure PO 2.06.02.

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With reference to Item 2, SOV. 2.08A.01, " Boron Recovery System", will be done at the end of the HFT. This is one of the tests which was not shown in the procedure but is scheduled to be done, in part, during the HFT as required by the FSAR commitmen SOV 2.35.02, " Main Generator Electrical Test", is partly done during the HFT by reference to other procedures applicable to the various subsystems of the main generator, as follows:

Seal Oil System and Generator Air Test in SOV 2.35.01 (not during HFT)

Hydrogen and CO 2 System Test in S0V 2.35.03 (not during HFT)

Initial Generator and Exciter Checks in SOV 2.26.01 (during HFT)

The licensee did not feel it to be necessary te identify all of the systems scheduled to be tested during the HFT, under test objectives or test methods as long as each of the commitments in the FSAR for the HFT are met in the HFT procedur With reference to the last item, DLC Startup Management has committed to do a surveillance type test to obtain base line data on the RCS Leak Rate during the HF Findings The inspector has no further questions on the HFT procedure. This unresolved item is close . Preoperational Test Program 3.1 Test Procedure Review The test procedures listed in Attachment A were reviewed for admin-istrative and, selectively, for technical adequacy and to verify that test planning satisfies regulatory guidance and licensee commitment Discussion The test procedures were examined for the attributes listed in Inspection Report No. 50-412/86-1 For Procedure SOV 2.44C.05, it was noted that many jumpers are to be installed " momentarily" during the test to verify a number of system actions. It was escertained that these jumpers will be hand held during their application and, indeed, will be in the circuit for just a moment. The inspector had no other questions on these procedure .

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FINDINGS No unacceptable conditions were noted in the procedures reviewe .2 Test Witnessing Scope Selected steps of Phase-2 Procedure P0 2.15A.01, " Component Cooling Water", and Phase-1 Procedure 2T RHS-10-2.02, " Residual Heat Removal System" were witnessed. Test Witnessing included observations of the attributes in Section 3.2 of inspection report 50-412/86-2 Discussion The steps of Procedure Section VII J of Procedure P0.2.15A.01 were witnessed for the flow balance of the Neutron Shield Tank Cooler, 2 NSS-E21. The target for the flow rate to this cooler was 30 gp A clamp on type flow meter (Controlotron) was used temporarily for the test. Globe valves 2CCP-DCV100-1 and 2 were used to adjust the flow rate to the cooler. The inspector also reviewed the calibration and application of the Controlotron. Transducers and circuit cards have to be matched for a given application in terms of pipe size, wall thickness, and pipe materia Calibration information and identification of card and transducers was as follows:

Card: I-II-2.5418.1- Calibrated: August 28, 1986 Due for recalibration: August 28, 1987 WD-1.5CS80 (size, material, wall thickness)

VM-D2, SN 1496 Used with 961 WP-CSS.16-18113 (Transducer)

Transducer: 961 WP-CSS.16-18113 W/ thickness /rmg .194 .218 SN467 Calibrated: October 22, 1986 Due for recalibration: October 22, 1987 The Controlotron System 960 was used. A list of matching cards and transducers was reviewed to confirm that the right matching pair was used in this particular applicatio It was concluded from this inspection that the test coordinator for this test was familiar with the requirements of this test equipment and that the equipment was functioning properly. The installation requirements for the transducer installation were checked in situ using the available installation and maintenance manual. No unacceptable installation conditions were foun .

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The Phase-1 test for the RHR system was a retest to obtain more accurate pump performance data for pump 2RHS*P218. It was noted that the test engineer verified all prerequisites and initial conditions with a new copy of the test procedure. This time Heise test guages were used on both the discharge and suction side. In the first test a Heise gauge was used on the suction side only. A total of 5 points on the total developed head (THD) versus flowrate curve were obtaine Flow control was obtained via valves 2RHS*FCV605 A and These valves are butterfly valve Since flow control with these valves is difficult for flow rates above 2000 gpm, the inspector will further assess the use of butterfly valves in this flow control application in a future inspectio This will be tracked under unresolved item 412/86-38-02. No other unacceptable conditions were noted during this tes Findings No violations were identifie .3 Test Results Evaluation Scope The test results for the Phase-1 tests of the Emergency Diesel Generators, EDG-1 and 2, as listed in Attachment B, were reviewed for the attributes listed in Inspection Report No. 50-412/86-11, Section Discussion Item 1 is called a retest of 2T-NNS-36B-2.24 (Item 2) but is really a separate test which should have been included in Item 2 but was no The criteria for cylinder exhaust temperature, firing pres-sures, and fuel rod settings were not me Item 2 as well as the other items have unfinished test summarie The test results are approved for a test that basically has valid test results but still has some deficiencies which require correc-tio The deficiencies are tracked on a deficiency list. When correction of the deficiency is achieved, the results of any retest, however, are not included in the original test package. Based on discussions with the licensee startup management, the results of any retests would be provided with the packages the inspector selects for revie For Item 3 a high delta P was experienced twice on the simplex lube oil strainers during the test. The licensee attributed this to system preservatives plating out on the strainer after going into solution at the high lube oil temperatures. Also, the iube oil system had not been flushed prior to the test because it was not considered necessar _ _ . _ . - _ - _ - - _ _ - - - _ _ ._ ___ ._

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A test log was not included in the test repor The test engineer said that it was not required for a proof test (Phase-1) per the Startup Manual but that for the more complicated tests it may be included at the initiative of the test enginee For Item 5, the fuel pump was replaced twice for No. 5 cylinder and once for No. 6 cylinder. After these failures a flush of the fuel oil piping on the skid was done. The inspector noted that similar

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problems had been experienced at another nuclear plant. The causes in that case were bypassing of the fuel oil filter due to warped filter support plates and hideout of casting sand in a casting pocket in the filter head located at the outlet of the filter. The first problem was corrected by changing the design of the filter support plates, the second problem by ultrasonic cleaning of the filter-hea Although the filter units are from the same manufacturer (Nugent), it is not known whether the filter models are the same and have the same revised filter support plate desig These filters (spare parts)

will be inspected in a future inspectio The test log for Item 5 shows a high delta P on the oil strainer (greater than 25 psi). The licensee does not anticipate that a similar high delta P buildup will occur in future operation of the EDGs. The inspector observed at two other nuclear plants, a black deposit formed on the oil strainers similar to that found at BV- The inspector requested that the strainer deposit be checked for carbon content since the deposit may not be the system preservative but soot buildup in the oil due to normal use of the diesel engin If that is the case, the delta P problem would return. The inspector will continue to follow this item in a future inspectio In Item 6 there is an attempt to determine fuel consumption. There were no criteria to evaluate the acceptability of this fuel con-sumptio Fuel consumption will determine the required size for the fuel oil tank under accident conditions (7 days at full load). The inspector was informed by the test engineer that this would be ac-complished in the Phase-2 tests of the diesel All of the questions identified above for all of the test reports reviewed will be addressed under Unresolved Item 412/86-38-0 Findings No violations or deviations were iGentifie . Independent Inspection Effort 4.1 Status of Main Steam Isolation Valves (MSIVs)

A temporary test facility i as being completed at the site to test the MSIV operators. Plans are taking shape to convert the electro /

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hydraulic system to air / hydraulic to obtain more power to initiate the hydraulic actuation of the valve. The inspector visited the facility to obtain first hand information on the status of the fa-cility and the plans for testing. Two of the valve operators were being mounted on their test stands. The third operator is at the Crosby factory for dwell testing. The solenoid towers on the exist-ing operators will be removed. Preparations for the second actuator control box and the installation of the new air cylinder are under -

way. A site testing plan is being formulated. The testing should provide the necessary input to make a final determination on the corrective actions to be taken for the experienced generic problem .2 Status of Emergency Diesel Generator (EDG)

Scope The status of the EDG testing was determined. A tour was made of the two EDG buildings. The elapsed running time for each EDG was establishe Discussion The two EDGs are essentially ready for Phase-2 testing (see Paragraph 3.3 above). The elapsed running time for the two EDGs are:

EDG-1 (2 EGS*EG 2-1) : 140 hours0.00162 days <br />0.0389 hours <br />2.314815e-4 weeks <br />5.327e-5 months <br /> EDG-2 (2 EGS*EG 2-2) : 271 hours0.00314 days <br />0.0753 hours <br />4.48082e-4 weeks <br />1.031155e-4 months <br /> The diesels are Colt-Pielstick, type 12 PC2V00, 514 rpm, 5900 BH The buildings for the EDGs were found in clean condition. The build-ing doors were locked. Keys for these doors were under control of the control room shift operations superviso Findings No unacceptable conditions were note .0 QA/QC Interface Scope Response by DLC startup management to Surveillance Deficiency Reports (SDRs) reviewed previously were examined for correctness and adherence to the requirements of the startup manua r--

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Discussion Responses to the following SDRs were examined:

SOV 32-86: SDR #1 OPS 03-86: SDR #1 In both cases the responses by startup management are acceptable. SDR #1 of OPS.03-86, however, cannot be closed out because the commitment made by startup management has not been completed within the required time period. This item also happens to be a repeat item. The inspector will followup on the completion of this item in a future inspectio Findings No unacceptable responses were identifie .0 Unresolved Items Unresolved items are matter about which more information is required in order to determine whether they are acceptable, an item of noncompliance, or a deviation. New unresolved items in this report are identified in Paragraphs 3.2 and .0 Exit Interview At the conclusion of the site inspection, on November 7, 1986, an exit interview was conducted with the licensee's senior site representatives (denoted in Section 1). The findings were identified and previous inspection items were discusse At no time during this inspection was written material provided to the licensee by the inspector. Based on the NRC Region I review of this report and discussions held with licensee representatives during this inspection, it was determined that this report does not contain informa-tion subject to 10 CFR 2.790 restriction .

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ATTACHMENT A to 50-412/86-38 PROCEDURE REVIEWS Approved by-Proc. N Procedure Titl Rev. N JTG P0-2.04.02 Emergency Shutdown and 0 7-30-86 Alternate Shutdown Panel (issue 1)

S0V-2.04.01 Condenser Steam Damp Test 0 7-30-86 (issue 1)

SOV-2,44C.05 Containment Air Recir Fans (issue 1)

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ATTACHMENT B to 50-412/86-38 TEST RESULTS EVALUATION Proc. N Approved Date Item DLC Doc. N Procedure Title Rev. N Test Results 1 2T-NNS-368-2.24 Open Item 10026: 0 5-09-86

@ Engine Balancing S-0705 at 100% load (on Retest Form)

2 2T-NNS-368-2.24 Initial Loading of G 6-02-86 S-0679 Emergency Diesel Generator (EDG),

2EGS* EG 2-2 3 2T-NNS-36B-2.21 Initial Loading of 0 12-26-85 S-0531 EDG, 2EGS*EG 2-1 4 2T-NNS-368-2.22 Initial Operation 0 12-26-85 S-0532 and Checkout of EDG, 2EGS*EG 2-2 5 2T-NNS-368-2.23 Initial Loading of 0 04-02-86 S-0560 EDG, 2EGS*EG 2-1 6 2T-NNS-368-2.25 Air Start Cylinder 0 05-29-86 Capacity and mis-cellaneous testing of EDG, 2EGS*EG 2-1 9 - Related to procedure shown but not a part of i _ - _ - _ _ _ _ - _ _ _ _ _ _ - _ _ - _ _ _