IR 05000423/1985043

Insp Rept 50-423/85-43 on 850805-09.No Noncompliance Identified.Major Areas Inspected:Preoperational Test Program,Including Test Procedure Review,Test Witnessing,Test Results Evaluation & Emergency Diesel Generator Test Status

ML20133C924
Person / Time
Site:	Millstone
Issue date:	09/26/1985
From:	Chen U, Eselgroth P, Vankessel H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20133C919	List: IR 05000423/1985043 ML20133C915
References
50-423-85-43, NUDOCS 8510070538
Download: ML20133C924 (16)

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k l U.S. NUCLEAR REGULATORY COMMISSION

REGION I

, Report N Docket N ,

License No. CPPR-113 Category B Licensee: Northeast Nuclear Energy Company

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P. O. Box 270 Hartford, Connecticut 06101 Facility Name: Millstone Nuclear Power Station, Unit 3 Inspection At: Waterford, Connecticut

, Inspection Conducted: %A ugust 5-9, 1985 W/ 7 Inspectors: U/ .

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H. F. VdnKeisel ~ Readtor ' Engineer date I

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' date Approved by: e .

P. W. Eselgrotti,4hief

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! Test Programs Section, 08, DRS Inspection Summary: Inspection on August 5-9, 1985 (Inspection No. 50-423/85-43) i-Areas Inspected: Routine unannounced inspection of the preoperational test program, including test procedure review, test witnessing, test results eval-l uation, emergency diesel generator test status, engineered safeguard test

status, Quality Assurance and Quality Contro Results: No items of non-compliance were identified.

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I 8510070538 850927 3 j DR ADOCK O

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DETAILS 1.0 Persons Contacted Northeast Nuclear Energy Company (NNECO)

A. Andreae, QC Supervisor M. Brown, I&C Supervisor R. Cikatz, QC Supervisor J. Chunis, Startup Engineer D. Dickerson, Startup Engineer E. Fries, Startup Engineer R. Grebasch, Startup Engineer N. Hulme, Startup Engineer J. McConnell, Startup Engineer D. McDaniel, Startup Engineer

• D. Miller, Jr. , Startup Manager S. Sudigala, Assistant Startup Northeast Utilities Service Company (NUSCO)

A. Gulesserian, Project Engineer L. Nadeau, A. P. Engineer

• E. LaWare, QA Engineer R. Vogel, Project Engineer Stone and Webster Engineering Corporation (SWEC)

• G. Basilesco, Engineer W. Matejek, Project Advisory Engineer U.S. Nuclear Regulatory Commission (USNRC)

• T. Rebelowski, Senior Resident Engineer

• Denotes presence at the exit meeting on August 9, 1985 Licensee Actions on Previous Inspection Findings 2.1 (0 pen) Unresolved Item 423/85-10-01, Vibration Induced Valve Failures Reference:

Memorandum J. O. Crockett to Distribution, Northeast Utilities, NNEC 3-2617, " Valve Position Indication (VPI) Concerns", dated July 29, 198 .

Status The status report entitled " Valve Position Indication Problems", a SWEC report is attached to the referenced memorandum issued by the

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Unit 3 Superintenden In this memorandum, the resolution of the remaining problems, as listed in the SWEC report, is tied to the Hot Functional Test as a prerequisite for sam Although most problem identifications for the various systems have been made, there is much work on Design Deficiency Reports (DDRs),

"Unsats", and Engineering and Design Change Requests (E&DCRs) left to be done. The inspector will continue to follow the licensee's cor-rective actions on this ite .2 (Closed) Unresolved Item 423/85-02-02, Fuel Handling problem References (1) Letter from J. J. Dolan of Westinghouse to S. Orifice of North-east Utilities Service Company (NUSCO), " Millstone Nuclear Power Station Unit No. 3, Fuel Handling Machine W/FDR-NEUM-10266", dated July 22, 1985, with attachment: Field Deficiency Report NEUM-10266, dated July 22, 1985, " Hoist Overload LS Dead End Support".

(2) PMMS Work Order M3 85 22687, Trouble Report 22 M3032956, signed July 23, 1985, problem description: Reset Mechanical Overload; Replace mounting screws per Westinghouse letter WMP-0920 of July 22, 198 Discussion (1) Speed control problems were experienced on the New Fuel Receiv-ing Crane. The speed was considered too fast for up-endin The resulting start and stop type operations caused the re-sistor bank to burn ou (2) The load cell on the New Fuel Handling Crane was lost, resulting in loss of load indication. An in-line load indicator (Dillon)

was installed temporarily to continue with the fuel receipt operation (3) Two cutouts were experienced on the electrical load cell of the Spent Fuel Pool Bridge and Hoist. There was a loose wire on the clevis pin. This unit is controlled by a microprocesso The loose wire caused a short circuit in the circuit of the processor causing the digital readout to go to zero. At the same time everything came to a halt. The opt on of upward motion was lost. The loose wire problem also caused problems with the load settings of the computer load monitor. The me-chanical overload setting would drift. The limit switch setting in the hoist has a 200 lbs. tolerance which was felt to be too coars Problems (1) and (2) did not appear to be significant from a safety point of view. The problems were fixed and have not-re-appeared.

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Problem (3), however, had safety significance. At one point in the use of this hoist, the load went down by itself, without comman Westinghouse was approached to resolve this problem. A work order (Ref. 2) was issued to repair the hoist in accordance with the West-inghouse disposition of the problems as contained in reference 1 above. It is considered that all experienced problems have been re-solved satisfactorily. This unresolved item (423/85-02-02) is close .3 (0 pen) Unresolved Item 423/85-25-01, Fuel Oil Filter Location on EDGs, a Fire Hazar A Design Deficiency Report (DDR550) was issued to address the problem. The inspector will continue to follow the corrective actions taken by the License For further details on this item refer to inspection report 423/85-2 .0 Preoperational Test Program 3.1 Test' Procedure Review l Scope The test procedures listed in ATTACHMENT A were reviewed for acmin-istrative and, selectively, for technical adequacy and to verify that test planning satisfies regulatory guidance and licensee commitment Discussion The first approved preoperational test procedures (Revision 0), in-many instances, continue to be issued late for.NRC review. Approved test procedures are to be submitted to the NRC 60 days prior to the start of the test. Although many of those Rev. O procedures were reviewed by the NRC in draft form, their review has to be finalized before the test is perform-ed. The inspector concentrated on the review of the approved procedures (Rev. 0) which were issued since the last inspection period (423/85-38).

The procedures were examined for:

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Management review and approval

Procedure format

• Clarity of stated objectives

• - Pre-requisites

Environmental Conditions O

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• Acceptance criteria and their sources t

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• References

• Initial conditions-

• Attainment of test objectives

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' * Test performance documentation and verification  !

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• Degree of detail for test instructions

Restoration of system to normal after testing

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• Identification of test personnel 4 *

Evaluation of test data

Independent verification of critical steps or parameters i t

• Quality control and assurance involvement

, In accordance with the observations made in inspection report 423/85-25, special attention was paid to the restoration of the

. system in the procedur Findings 3 No noncompliances were identified'by the inspector within the scope

of this inspection.

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3.2 Test Witnessing l

Scope i

The inspector witnessed selected steps of the following Engineered Safeguard Features (ESF) and Hot Functional (HFT) related tests

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" Normal Station Service Transformer 15G-3SA", T3347 BA001',

i Step 7.11; Energize the transformer.

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" Charging Letdown and Purification Systems", T3304 AP001, Step 7.2.16; Valve Control logic check *

" Fuel Building Filter Exhaust Fans and Dampers", T3314 CIM02; Test run of Fan 10 Test witnessing by the inspector included observations of:

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Overall crew performanc s rw -' y- ,+ - y ,;w..--y , - - - . ,a- - - p .-

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Use of latest revised and approved procedure by test personnel.

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Designation of one person in charge of conducting the test *

Availability of sufficient test personnel to perform the test * Coverage of test prerequisite * Use of acceptance criteria to evaluate test result *

Verification that plant supporting systems are in service.

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In-service status of calibrated special test equipment required by j the test procedure.

Adherence to the test requirements of the test procedure during the test *

Timely and correct action by test personnel during the perform-ance of the test *

Date collection for final analysis by test personne ,

t The inspector independently verified readings of system parameters during the tests.

j Discussion

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The energization of the NSST transformer A, in accordance with Step 7.11 of procedure T3347 BA001, was witnessed by the inspector.

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No problems were encountere The valve logic checks, performed in accordance with procedure T3304 AP001, Steps 7.2.16.1 through 15, ran into a problem. A simulated signal was used to manipulate RWST level in order to actuate the valves 3GWS*PNLDI and 3HVR*RIC12. As required, form PU-590 was used in connection with the simulated signal. The desired valve action was not accomplished because of the failure of a card in the output cabinet. A DDR was generated by the test engineer to correct

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the problem. The test will be repeated after repairs have been accomplished.

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The test run of Fan 108 (3HVR*FN108) and its automatic shutdown, in accordance with test procedure T3314C1M02, was witnessed by the in-

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specto It was verified by the inspector that Fan 10B will start locally and can be secured locally. Fan 10A could not be run because train A was shut down electrically. Some problems were ex-perienced with the test run of Fan 10A on account of insufficient

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suction vacuum (-6" W.G. to be maintained). After controls were i

reset for -2.5":W.G. the fan could be run and the test was continue i Findings No noncompliances were observed by the inspector.

, 3.3 Test Result Evaluation Scope

, The test procedures listed in ATTACHMENT B were reviewed to verify that adequate testing was accomplished in order to satisfy '

regulatory outdance and licensee commitments and to ascertain

whether-uniform criteria were being applied for evaluating completed

preoperational tests in order to assure their technical and admin-1 istrative adequacy.

} r l Discussion i

The NRC review of the test results for the RCS Hydro, performed in accordance with test procedure T3301-P001, is considered to be pre-liminary because these test results have not yet been reviewed and approved by the Licensee.

, The test results were reviewed for:

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• Test changes

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Test deficiencies

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• Acceptance criteria

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Proper boundaries for the test syste Water quality as required.

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Minimum test pressure held for 10 minute (1.25 x minimum design pressure)

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Hydrostatic test pressure did not exceed maximum allowable j (6% above 1.25 design pressure).

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!~ - Reactor coolant temp. kept above the nil ductility transition temperature for RCS components.

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• Performance verificatio * Recording of conduct of tes * QC inspection record = System restoration to norma * Independent verification of critical steps or parameter * Identification of test personne *

Verification that the rest results have been approve The last item has not been accomplished yet. Test results of phase 1 tests of the Supplementary Leakage Control and Release System (SLCRS), as listed in ATTACHMENT B, were reviewed for the same gen-eral attributes as listed above but for different acceptance cri-

teri Findings No non-compliances were identified by the inspector within the scope of the revie .4 Emergency Diesel Generator (EDG)-Testing Status The 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> test runs for both EDGs have been accomplished success-fully. The 110% load portion of the acceptance runs, however, has not been done ye It will be done during the forthcoming ESF test A failure of the engine driven fuel oil pumps on EDG unit A was ex-perienced as a result of dirt introduced into the system during a piping modification. The pump was replaced with a new pump. This pump is a screw type pump. The dirt contained metal filings which seized the pump. The piping modification had been planned for some time but could not be done until recently. The work order for this piping modification was identified as PMMS Nuclear Work Order M3-85-17518. This work order clearly states in a note under the job description / procedures

" Maintain Cleanliness." The work was per-formed under the guidance of E&DCR T-P-0468 Findings It is not clear how the dirt was introduced into the fuel oil system but it is clear that the cleanliness instructions were not l

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observe The inspector will follow up on this unresolved Item (85-43-01) in a future inspectio .5 ESF Tests Testing Status The schedule for the integrated ESF tests, 3 INT-2003 and 4, is firming up. It is presently scheduled to' start in mid-August. The items, presently on the critical path are the HVAC systems which support the ESF tests. These HVAC systems include the SLCRS (Supp-lementary Leak Control and Release System) and the Auxiliary Building HVAC (HVR-A). Other critical path items are the Service Water (T3326-P) and the Reactor Plant Component Cooling System (T-330AP). Some test witnessing and procedure review was accomp-lished for these systems as noted in paragraphs 3.1 and 2 abov Findings No non-compliance was identified by the inspector within the scope of this revie . QA/QC Interface Scope The participation of NNECO-QC in the surveillance program for the pre-operational tests was reviewed and evaluated by the inspector. The pri-mary objective of this inspection was to determine how the efforts of NNECO-QC supplemented the efforts of NUSCO-Q Discussion The QC activities conducted by NNECO-QC were discussed with the supervi-sors of two groups within NNECO-QC. The first unit deals exclusively with the QC requirements for AW0s (work orders) as they relate to the startup program. This group does not get involved with the preoperational tests (POTS). The other group, the Surveillance Group, does get involved with the POT Several NNECO Surveillance reports, as listed in ATTACHMENT C were re-viewed by the inspectors for scope of inspection and the nature of the findings. While no hold points are used in the work performed by the Sur-veillance Group, the first group does use QC hold points. The work done by this group under AW0s are items of repair, adjustment, or design modifications and changes. The desired hold points are identified on the AWO by the responsible NNECO discipline. NNECO has the option to

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i give the work to SWEC if NNECO cannot or does not want to handle the wor In that case the work is done by SWEC under a Construction Work Permit (CWP) and any associated QC work is done by SWEC-Field Quality Control (FQC).

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The review of the surveillance reports revealed that NNECO-QC does impor- '

tant surveillances which in their depth of scope, significantly supp-lement the work of NUSCO-Q Findings l No non-compliances were identified by the inspecto ,

5. Independent Inspection and Measurements 5.1 Controlotron Flow Meter References Letter from W. M. Patterson of Controlotron Cor, '- to Stone and Webster Engineering Corporation, on interchangeabi hty / the Con-r trolotron equipment on carbon steel and stainless steel siping of

the same dimensions (diameter and wall thickness), dater. March 20, 1985.

J Scope The Controlotron flow meter is being used both as a permanent and as a temporary instrument to measure flow rates during the preoperation-al tests. Some problems have been experienced with the use of the

flow metering as a temporary installation, during the preoperational i

tests. The objective of this inspection was to determine if this flow meter could yield reliable and repeatable results for both stainless and carbon steel piping installation Discussion The Controlotron flow meter works on acoustic principles and has i digital readout of the flow rat It uses a sender and receiver

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which have to be timed to obtain a maximum signal. Transducers and pre-amplifiers have to be-matched. The flow measurement is dnrived from the time differential between the time measured for travel of the signal against the flow direction and the time measured with the flow directio The important components of the measuring system ,

have to be matched with the given pipe diameter, wall thickness (schedule of pipe), and pipe material. If the installation of the

Controlotron uses unmatched components, or is installed improperly, the flow meter will recognize these conditions and will go into a fault mode. The inspector observed this phenomenon on the use of a

- portable Controlotron in the Auxiliary Feedwater Pump Test as re-ported in a previous inspection report. The digital readout does not show any numbers when it goes into the fault mode. In this observed case, it was not possible to get a readout above 500 gpm (showed F

for Faulted). NNECO I&C felt that the instrument yielded accurate

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results ( 2%) everytime they had used it or observed i The in-strument, however, is very sensitive to fluid turbulenc They felt that the failure experienced during the AFE Pump test probably was

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due to excessive water turbulence too close to the instrumen NNECO I&C had heard about the alleged difference in results between carbon steel and stainless steel piping installations for the Con- '

troletron. The manufacturer (Controlotron) had been approached on this issu Reference 1 above is their answer to this questio Controlotron feels that the instrument is interchangeable on carbon

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Discussions held with one of the startup engineers revealed that he had not been able to get good flow measurements from the Control-otron when used on stainless steel piping.

i The inspectors will continue the review of this instrument on a future inspection.

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Findings No violations were identified within the scope of the review.

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5.2 Identification of Fuel Oil Filter Parts

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The identification of the components of the fuel oil filters of the

' Emergency Diesel Generators was pursued. These filters had design deficiencies which were corrected by the manufacturer (Nugent). The i Licensee replaced the complete filters including the housings. The objective of the inspection was to verify that the identification of the new filter component was maintained throughout purchasing,

! storage, and installatio ,

Discussion All the paperwork associated with the filter modification was re-

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viewed during inspection 423/85-25. It was found to be in order up to the vendor identification of the modified parts. There were no vendor drawing revisions available in the file to identify the

, design changes made to the filter internals. In addition there are no changes to the part numbers to differentiate the modified parts from the old parts. The Licensee was asked to contact the vendor to

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obtain positive identification of the new filter. parts. The

licensee has agreed to do that. The licensee, also, will destroy

, the old spare parts. This action by itself, however, does not

! ensure that the vendor will supply the new modified parts in future spare part shipments.

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Findings Positive identification of the modified filter components has not been achieved to dat The inspector will continue to follow corrective action on this Unresolved Item (425/85-43-02).

6. Exit Interview At the conclusion of the site inspection on August 9, 1985, an exit meeting was conducted with the licensee's senior site representative's (denoted in Section 1). The findings were identified and previous in-spection items were discusse At no time during this inspection was written material provided to the licensee 'oy the inspector.

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The Licensee confirmed that no proprietary information had been supplied to the inspector by them during this inspectio s I

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ATTACHMENT A 423/85-43 Reviewo{PreoperationalTestProcedures

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Proc.N Title Re Approval Date

- 3 INT-3000 Pipe & Pipe Suppo'rt Transient Vibration 0 7-18-85 App. 3021 Testing

- 3 INT-3000 Remote Shutdown with Cool down 0 7/08/85 App. 3014

- 3 INT-2001 Engineered Safeguards System Actuation 1 7-16-85 App. 3TS without loss of Power

- T3349-P001 Communications Testing 0 7-11-85 App. F01

- T3410 BP Reactor Vessel Level 0 7-25-85

- T3404-P Digital Radiation Monitor System 0 8-07-85

- T3341AP Fire Protection (Water) 0 7-22-85

- T3337-P Radioactive Gaseous Waste System 0 8-02-85

- T3304CP Boric Acid System 0 7-23-85

- T3311AP Reactor Plant Sampling 0 8-07-85

- T3313AP Hydrogen Recombiner/ Monitor and 0 7-12-85 Ventilation

- T3311CP Post Accident Sampling System 0 8-02-85

- T3329-IF01 Condensor Air Removal 0 10-20-84

- T3319AP Condensate System 0 6-15-85

- T3329A Air Removal Condenser 0 5-15-85

- T3323DA Gland Seal Steam System 0 2-27-85

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ATTACHMENT B 423/85-43 Test Result Evaluation Proc. N Title Rev. @ proval Date T3301-P001 RCS Cold Hydro 0 2-21-85 T3314IIIO1 SLCRS System Instrumentation 0 2-22-84 T3314I1E01 SLCRS Exhaust Fan 0 12-27-83 T3314I1M03 SLCRS Valves and Dampers 0 10-24-82 l

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ATTACHMENT C 423/85-43 Reviewed Surveillance Reports Report N Title Approval Date NUSCO-QA TC3699 Auxiliary Building Phase-1 Startup Test 8-01-85 TC3683 New Fuel Building New Fuel Handling 7-18-85 TC3685 MP-3 Service Water Test 7-22-85 TC3647 Intake Structure / Screen house 6-24-85 TC3650 Turbine Building (TB) EHC System 6-24-85 TC3652 Turbine Building Condensor Air In- 6-25-85 Leakage Tests TC3654 Condensate Polishing 6-25-85 TC3656 Turbine Building Helium Gas Analyzer 6-25-85 Erratic Response TC3657 TB-Waterboxes Cathodic Protection 6-25-85 TC3659 Turbine Building Lube Oil System 6-27-85 TC3660 Screen House 6-27-85 TC3663 TB-Main Feed Pump Turbine 7-03-85 TC3672 TB-RTD Failures 7-11-85 TC3674 TB-Condenser Flanged Bolts Failure 7-12-85 TC-3701 TB-Condenser Sand Blast / Epoxy 8-02-85 the Inlet Water Boxes NNECO-QC 585-41 QSS Chem. Addition Tank Drawdown 3-30-85 585-42 Containment Control Room Fuel Pool 3-30-85 ESF, Aux. Building 585-40 QSS Chem. Addition Tank Drawdown Phase 2 3-30-85

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585-72 Steam Generator 10 J Nozzle Replacement 6-18-85

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585-52 RCS Fill and Hydrostatic Test 4-27-85 T3301-P001 585-53 RCS Fill and Hydrostatic Test 4-30-85 T3301-P001 585-92 SIT /ILRT; 3 INT 2002 7-20-85

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