IR 05000412/1987036

Insp Rept 50-412/87-36 on 870420-24.No Violations Noted. Major Areas Inspected:Preoperational Test Program,Including Witnessing Preoperational Test,Review of Tests,Review of Test Repts & Status of Review of Test Deficiencies

ML20214Q073
Person / Time
Site:	Beaver Valley
Issue date:	05/20/1987
From:	Florek D, Vankessel H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20214Q071	List: IR 05000412/1987036 ML20214Q068
References
50-412-87-36, NUDOCS 8706040226
Download: ML20214Q073 (12)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

Report N /87-36 Docket N License N CPPR-105 Priority -

Category B Licensee: Duquesne Light Company P. O. Box 4 Shippingport, Pennsylvania 15077 Facility Name: Beaver Valley Power Station, Unit No. 2 Inspection At: Shippingport, Pennsylvania Inspection Conducte - Apcil 2Q-24, 1987 Inspectors: d 6) [

H. vanKbssel, Reactor Engineer, DRS 'datd Approved by: -) )

D. Florek Chief, Test Program Section, I dite 08, DRS Inspection Summary: Inspection on April 20-24, 1987 (Inspection N /87-36)

Areas Inspected: Routine Unannounced Inspection of the Preoperational Test Program, including the witnessing of preoperational tests, the review of pre-operational tests, the review of preoperational test reports, the status of review.of Test Deficiencies, the review of activities in the QA interface, and the review of unresolved items identified by the inspector in previous inspection Inspection Results: No violations were identifie NOTE: For acronyms not defined refer to NUREG 0544, " Handbook of Acronyms and Initialisms".

8706040226 870521 PDR ADOCK 05000412 G PDR ,

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DETAILS Persons Contacted Duquesne Light Company (DLC)

T. Brown, Test Engineer

• R. C. Callaway, Test Supervisor, Phase-2

• D. L. Claridge, Compliance Supervisor

• N. J. Daugherty, Director Systams Testing

• J. J. Dusenberry, Assistant Director QA Surveillance D. L. Dygert, Test Engineer

• J. P. Godleski, Senior Test Engineer P. A. Gonderson, Test Engineer

• D. C. Hunkele, Director QA Operations

• T. P. Noonan, Assistant Plant Manager F. R. Michael, Test Coordinator

• T. P. Noonan, Superintendent Operations and Maintenance R. V. Oliveri, Test Engineer

• L. M. Rabenau, Lead Compliance Engineer P. Slifkin, Test Supervisor, Phase-1

• G. R. Wargo, Assistant Director SQC

• L. P. Williams, Test Director, Phase-1 R. G. Williams, Software Development Supervisor U.S. Nuclear Regulatory Commission

• D. Florek, Lead Reactor Engineer

• L. J. Prividy, Resident Inspector, BVPS-2

• Denotes those present at exit meeting of April 24, 198 . Licensee Actions on Previous Inspection Findings (Closed) Unresolved Item 87-19-01, " Erratic Behavior of OT Delta T Circuit in Primary Process Racks" Scope It was noted during the performance of preoperational test P0.2.01A.02 that the trip bi-staoles for Loop 2 Over Temperature (OT) and Over Power (0P) Delta T were tripping erratically from causes unknow It was suspected that the use of walkie-talkies in the Control Building at the time of the test could have been the cause of this erratic behavior. The licensee planned to perform a test to check to OT and OP delta T circuits for sensitivity to radio frequency interferenc .

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Reference Memorandum D. L. Dygert to N. J. Daugherty, "NRC unresolved open

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items regarding erratic trips in Primary Process Racks", received April 25, 1987, Startup Work Request No. 013072, " Trip bistables for Loop 2, Chanel 2 OP and OT Delta T circuits are tripping erratically. Troubleshoot and determine cause."

Discussion The SWR (ref. 2) generated by the erratic operation of the trips was used to test the OT and OP circuits for sensitivity to radio frequency interference. Conditions present at the time of the erratic operation of the - trips were duplicated with only one exception (concrete block over equipment hatch).

Prior to this test, the OT and OP circuits were recalibrated. A number of defective cards were found in the Loop 2 temperature circuits and the lead / lag circuits were far out of calibration (see ref. 1).

No spurious operation of any process equipment was ' observed during the test which used a portable radio in the immediate vicinity of the process equipment and, also, in the immediate vicinity of the SSPS equipmen It is concluded in re ference 1 that the most probable cause of the experienced erratic behavior was the circuits being in a near trip condition with the circuits far out of calibration while radio frequency interference was presen Conclusion The problem was corrected by recalibrating the OP and OT circuits. The inspector has no further questions on this unresolved ite (0 pen) Unresolved Item 86-38-01, " Emergency Diesel Generator Discrepancies".

Scope The review of the test results for the Phase-1 tests of the Emergency Diesel Generators, EDG - 1 and 2 identified 6 open items as listed in Inspection Report No. 50-412/86-11, Section Reference Inspection Report 50-412/86-40 for inspection completed on November 21, 198 ..

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. In'spection Report 50-412/86-43, for inspection completed on December 19, 198 . Memorandum D. McBride to J. Godleski, "NRC Diesel Generator Audit",

received on April 15, 198 . Test Deficiency Report TDR-2793 for subsystem package 368-1FB, Diesel Generator 2EGS*EG2-2, dated May 27, 1986, retest approved May 29, 198 . Report S-0790 for retest of EDG2-2 at 100% load to obtain firing pressures' for all cylinders, prepared on June 24, 1986, test completion approval on June 28, 198 . Conversation Memorandum TLC-68, between Messrs. E. Freeman of DLC/SUG and J. Johnson of Colt Industries, dated June 27, 1986, "EDG 2-2 Engine Balancing Data". Memorandum dated and initialed December 2, 1986, " Maintenance Response to UNR 86-38-01." Startup Work Request 012887 and 8 for Lube oil strainer block deposit analysis, issued en February 26, 198 . Memorandum DLC, J. Godleski, " Fuel Consumption measurement for EDGs"; dated November 17, 198 Discussion For Subitem 1; failure to meet criteria for cylinder exhaust temperatures, firing pressures and fuel rod settings: TDR-2793 (ref. 4) was issued to cover the deficiencies. Fuel rod settings were adjusted and a retest was successful. The retest is reported in Report S-0790 (ref. 5). The test results were discussed with Cold Industries and were accepted by them (see ref. 5). The inspector has no further questions on this subite For Subitem 2; inclusion of retest information and results in the final test package: The licensee will include all TDRs, SWRs, and copies of retests will be included in the S-0679 package. This subitem will remain open until all retests and repairs have been completed and the pertinent information has been reviewed by the inspecto For Subitem 3; experienced high differential pressure across the simplex lube oil strainers: The licensee attributed this problem to system preservatives plating out on the strainer after going into solution at the high lube oil temperature No recent problems with high differential pressure have been encountered. The inspector has no further questions on this subite .

For Subitem'4; fuel oil filter bypassing and casting sand hideout problem:

The licensee discussed this subitem with the other nuclear plant (see re above) which had experienced these problems. The Nugent filter assemblies at BVPS-2 are different. The cartridge support springs are attached directly to the support plate. Also, no leading of casting sand from the filter housing castings has been observed by DLC/SU The inspector has no further questions on this subite For Subitem 5; check for carbon content of black deposits found on lube oil strainers: The licensee has initiated two Startup Work Requests (re ) to analyze the black deposit on oil strainers for carbon conten The results of this analysis will be- forwarded when complete This subitem will remain open entil the work has been done and reviewed by the inspecto For Subitem 6; criteria to evaluate the acceptability of the fuel consumption: The licensee has reviewed the pertinent Phase-2 EDG test procedures to determine where this fuel consumption is determined and what the fuel consumption accident criteria are for same. In reference 9 it is noted that this is done in P0 2.368.0 The fuel consumption accident criteria is smaller or equal to' 5.28 gp The inspector has no further questions on this subite Summary Conclusion Four ubitems are closed and two subitems remain open (2 and 5). The inspector will follow up on these two subitems in a future inspectio . Preoperational Test Program 3.1 Preoperational Test Witnessing Scope Selected steps of the preoperational test procedures, identified below, were witnessed. Test witnessing includea observations of the attributes listed in Section 3.2 of Inspection Report 50-412/86-2 piscussions Steps VII.03 ar.d VII C.3 of procedure P0-2.01A.04 for relays K643A and K607A respectively, were witnessed. No problems were encountered and no test deficiencies were generate The inspector also witnessed the start of the 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> run at full load on EDG 2-2, performed under procedure P0-2.36B.0 In the warmup phase, breaker 2F7 tripped for unknown reasons. The EDG 2-2 dropped load, from 4.200KW (full load) to 1300 Kw. The EDG took this unexpected load transient very wel It stabilized at 1300 Kw

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, 6 without a problem. Over current relay Y2943 was identified to have caused the breaker tri The breaker was reset and the testing continue The inspector made independent cylinder exhaust temperature readings after the first hour of operation at full load, as follows:

Cycl. N Temp. 'F 1 840 2 780 3 830 4 835 5 890 6 890 7 850 8 830 9 820 10' 880 11 860 12 860 It was noted that cylinder 2 still is reading too low (110 F difference with highest temperature). Recalibration has not been done ye The 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> run was not complete Problems were experienced with inadequate fuel oil return flo The EDG had to be shut down to investigate tnis problem. A test deficiency was generated for this problem. It is suspected that there may be an obstruction in the fuel oil return lin Findings No unacceptable conditions were note .2 Preoperational Test Result Evaluation Scope The Test Result Reports (TRRs) for the test procedures listed in Attachment A were reviewed to verify that adequate testing was accomplished in order to satisfy regulatory guidance and licensee commitments and to ascertain that uniform criteria were being applied for evaluating completed preoperational tests to assure their technical and administrative adequac .-_- - ,_ - , . _- - - - ..-.- . -., , . - . . . - _

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Discussion

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The TRRs were reviewed for'the attributes listed in Inspection Report 412/87-19 . Each TRR was reviewed together with the file containing the completed original of the procedure and the correspondence associated with completed work and retesting for identified test deficiencie In test procedure P0-2.07.01 improper scale adjustment on the stripchart recorder caused the collected data for pumps P21A and B to be unreadable. Data from another test were substituted for the

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missing data without generating a test deficiency. While such a substitution could be acceptable under certain circumstances, a justification for same was not available because a test deficiency report was lacking. . The inspector will followup on this problem under Unresolved Item 412/87-36-0 In procedure P0-2.11A.05 test deficiencies 13 and 14 were written against 2 SIS *HCV868 A and B because the valve position indicators were not matching set points at 100%. Further evaluation by Engineering and DLC/I&C indicated that the valves were stickin The 8688 valve was stroked dynamically during SIS flow tests. Based on the results both TDRs were closed. There are, however, still questions unresolved on these valves as evidenced by Request for Information, RI (SUG) 2617. A recent retest with thase valves indicates that the valves still are stickin The inspectors will followup on this item under Unresolved Item 412/87-36-0 Findings No violations or deviations were noted by the inspector. The inspector will followup on the two Unresolved Items 412/87-36-01 and 0 .3 Test Deficiencies Scope Only one retest (TD) was identified in the TRRs discussed under paragraph 3.2 above. This TD will be tracked by the NRC to completio It will also be evaluated for safety significance and the timing of completion relative to the major milestones of the startup progra Discussion

It is planned to assign an Unresolved Item number to all of the open TDs and retests as soon as the NRC test result evaluations effort-approaches 80%. A summary listing will then be produced together with the evaluation of the safety significance of the listed TD ... . - -

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Test Deficiency No. 2 of procedure P0-2.47.11 requires a replacement of valve 2CHS*FCV-160 on account of excessive leakage (>631 cc/ min).

After replacement of the valve, it will be retested. It is recorded as Retest Log No. 47-00 Findings No non-compliances were identified by the inspecto .0 Independent Inspector Effort 4.1 Independent Calculation of Leak Rate for Containment Type "C" Leak Rate Test Scope-Based on test cata obtained during the performance of preoperational test P0-2.47.01, the inspector calculated the leak rate of penetrations X-21 and X-2 Reference Test Procedure P0-2.47.01, " Containment Type "C" Leak Rate Tests". Revision 0, approved by JTG on June 26, 1986; Data sheets 1 and 2 for X-21 (page 100 and 101) and for X-24 (page 109).

Conclusion Ne errors were found in the leak rate calculations for penetrations X-21 and X-24 in the data sheets of reference 1 abov .2 Status of MSIV Replacements The valves have not been received yet at the site. Wiring and piping installation for the valve auxiliaries is proceeding on schedule. Phase-2 test procedures for the valves are being prepare .0 QA/QC Interface Scope The participation of the Duquesne Light QA Surveillance Group in the preoperational test program was evaluated by the inspector. A number of selected surveillance check lists for preoperational tests, as listed .in Attachment B, were reviewed for adherence to the requirements of the Startup Manua I

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'. 9 Discussion The selected Surveillance Checklists of Attachment A included surveillances for preoperational tests PO-2.01A.02, "RPS/ESFAS Time Response Tests", P0-2.01A.04, " Safeguards Test Cabinet Actuation Test",

and P0 2.36B.01, "EDG System Test". All of these tests have been completed recently or are still in progres All of the Surveillance Checklists reviewed indicated fully satisfactory performance by the test engineers and supporting operating personne The inspector had no questions on any of the listed surveillance Findings No unacceptable conditions were noted by the inspecto .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 repcrt are identified in paragraph . Exit Interview At the conclusion of the site inspection, on April 24, 1987, 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 information subject to 10 CFR 2.790 restriction l

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MANHOURS VERSUS MODULES IR No.: 412/87-36 Date Prepared: 4/23/87 Test Witnessing: Module %C Mhrs() Mhrs() Mhrs()

• P0-2.01A.04 (4 Relays) 70313 100 16

• PO-2.36B.02 70441 70 4 Test Results Evaluation

• P0-2.11A.05; Misc SIS-MOV. 70329 30 2 (A-C)

• P0-2.07.01, Chg Pumps 70533 30 3 Controls (GH.1)

• PO-2.47.11, Ctmt. Pe Valves Int. Test (A-H)

• PO-2.15B.01, Nuclear S Tk Chg Test (A,B)

• P0-2.47.01, Ctm (All) Type C LRTs

• P0-2.02.01, NIS 70554 25 2 (A,B)

PO-2.47.09, Per (All) Air Lock Ope * P0-247.10, Equi (All) Lock Oper' Test QA/QC Interface Review of QA Sur Independent Efforts 71302C (95)

• MSIV Status 2 Calcs on LR x 21/24 1 Meetings

• Entry / Exit 30703 -

Open Items 71302 65 3

• Update 86.38-01 CDG

• Close 87-19-01

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o ATTACHMENT A to IR 412/87-36 TEST RESULTS EVALUATION Approval Date l Proc. N Title Rev.No. TRR by JTG l P0-2.11A.05 Misc. Safety Injection MOV 0 3-27-87 ,

(Sect. A-C) Control and Alarm Test l PO-2.07.01 Charging Pumps and Controls 0 4-10-87 (Sect. G, H, I) Test P0-2.47.11 Containment Penetration Valves 0 4-03-87 (Sect. A-H) Integrity Test P0-2.15B.01 Neutron Shield Tank Cooling 0 3-09-87 (Sect. A&B) Test i

P0-2.47.01 Containment Type C Leak 0 4-10-87 (Sect. All) Rate Test P0-2.02.01 Nuclear Instrumentation System 0 4-03-87 (Sect. A,B) Test PO-2.47.09 Personnel Air Lock Operability 0 4-16-87 Test P0-2.47.10 Equipment Hatch / Emergency 0 4-16-87 Airlock Operability Test

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ATTACHMENT B to IR 412/87-36 REVIEW QA SURVEILLANCE REPORTS Su Surv. N Proc.N Proc. Title Compt. Date POT-81H-87 P0-2.368.01 EDG System Test 2-14-87 (Sect. H)

P0T-81D-87 P0-2.368.01 EDG System Test 3-26-87 (Sect. D)

POT-44T-87 P0-2.01A.02 RPS/ESFAS Time Response 4-03-87 (Sect. T)

POT-44S-87 P0-2.01A.02 RPS/ESFAS Time Response 2-28-87 (Sect. S)

P0T-44N-87 P0-2.01A.02 RPS/ESFAS Time Response 3-08-87 (Sect. N)

POT-44S-87 PO-2.01A.02 RPS/ESFAS Time Response 2-28-87 (Sect. S)

POT-440-87 P0-2.01A.02 RPS/ESFAS Time Response 3-18-87 (Sect. 0)

POT-441-87 P0-2.01A.02 RPS/ESFAS Time Response 2-24-87 (Sect. I)

POT-44L-87 PO-2.01A.02 RPS/ESFAS Time Response 4-08-87 (Sect. L)

POT-45F-87 P0-2.01A.04 Safeguards Test Cabinet 4-10-87 Act. Test