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Insp Rept 50-483/87-24 on 870730 & 0804-07.Violations Noted. Major Areas Inspected:Nonconservative Setting of Overtemp delta-temp Reactor Trip Setpoint & Adequacy of Corrective Actions Specified in LER 87-012-01
	ML20238F444
Person / Time
Site:	Callaway
Issue date:	09/03/1987
From:	Darrin Butler; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:	;
Shared Package
ML20238F432	List: IR 05000483/1987024; ML20238F430; ML20238F439;
References
	50-483-87-24, NUDOCS 8709160160
	Download: ML20238F444 (43)
	v • d • e

{{#Wiki_filter:l I V y-U.S. NUCLEAR REGULATORY COMMISSION

REGION III

Report No. 50-483/87024(DRS) Docket No. 50-483 License No. NPF-30 Licensee: Union Electric Company Post Office Box 149 St. Louis, M0 63166 Facility Name: Callaway Nuclear Power Plant, Unit 1 Inspection At: Callaway Site, Callaway County, Missouri

Inspection Conducted: July 30 and August 4-7, 1987 , Inspector:

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    "0 ate Approved By: M. P. Phillips, Chief Operational Programs Section  Date l l

Inspection Summary Inspection on July 30 and August 4-7, 1987 (Report No. 50-483/87024(DRS)) Areas Inspected: Special announced safety inspection of licensee actions pertaining to the non-conservative _ setting of the OTAT reactor trip setpoint and adequacy of the corrective actions specified in Licensee Event Report No. 87-012-01 (IE Module No. 92700).

Results: One violation involving failure to set the OTAT reactor trip setpoint in accordance with Technical Specification requirements resulting in failure to comply with the LC0 action statement for all trip channels inoperable (Section 2).

k G. The inspector also interviewed other licensee personnel during the j course of this inspectio l 2. OTAT Reactor Trip Setpoint j Background l The Overtemperature Delta Temperature (OTAT) reactor trip setpoint is a variable setpoint which is designed to provide departure from j nucleate boiling (DNB) protection in the event of certain accident This setpoint utilizes inputs from the coolant loop temperature sensors which determine AT and T-avg for each loop, the pressurizer pressure sensors which determine primary system pressure, and the nuclear instrumentation which determines the axial flux differenc The nuclear instrumentation consists of two excore detectors for each channel, one monitoring the top half of the core and the other the bottom half. The axial flux difference (61) is determined by taking the difference between the upper detector and the lower detector (upper power - lower power). DNB protection is provided by ensuring that the localized power generated by the fuel elements

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n e is'not excessive in relation'to the given reactor pressure and-

temperature condition such that the primary system could experience boiling. :The OTAT reactor trip setpoint accomplishes..this protection by.being variable depending on the values of AI, T-avg, pressurizer, pressure, and AT. In the' case of AI, the reactor trip setpoint is-always lowered when.the value of Al exceeds a certain band in either direction, indicating excessive power production _in either the. top or bottom of the core. The specific limits are specified by Technical Specification On June 25, 1987, the licensee notified the NRC Headquarters Operations Officer that the circuitry which provides the correction to the'0 TAT setpoint based on changes in axial flux difference.(AI) was incorrectly scaled. The scaling had not been adjusted as required-following initial startup in November of 1984. The non-conservative scaling of AI would result in a. failure to decrease the OTAT setpoint as required by.the Technical Specifications (TS) as the axial flux difference became greater than +6% or 'less than -35%. The circuit-adjustments existing prior _to June 25, 1987, would not have lowered the OTAT setpoint unless AI was outside the band -70% to +12%. Subsequently, the licensee submitted Licensee Event Report No. 87-012 and an associated supplemental report No. 87-012-01, and requested a

management meeting to.present the results of their investigation into this event. The' management meeting was held on July 30_, 1987, and a copy of the material presented at the meeting is attached to'this report, Axial Flux Difference (AI) Scaling The AI circuitry is made up of isolation amplifiers, scaling potentiometers, AI' summing amplifiers, and a AI function generato A simplified electrical diagram is shown in the attachment. The licensee's-investigation into the AI scaling error determined that the AI circuitry had not been properly corrected based on the incore/ excore calibration conducted during and subsequent to initial startup testing.-_ This was caused in part by the following:

 (1) Inter-departmental misunderstanding of the required setpoint adjustments; (2) the JU-8000 document, " Instrument Setpoint Index,"

listed fixed gain values for the AI summer amplifier as specified in the initial startup instructions; and (3) there was confusion among the Instrumentation and Contr61 (I&C) personnel as to the interpretation of the term " Percentage Units" (PU) when calculating the scaling of the AI circuitr As a result of these contributing causes, licensee personnel failed to detect the error in the AI input to the OTAT setpoint despite performing two previous channel calibrations and several quarterly , adjustment The error was discovered when I&C personnel were unable ' to adjust the isolation amplifiers' gain sufficiently to obtain the required reading per the procedure they were using during the 1987 , calibratio The subsequent licensee investigation determined that the AI summer amplifier should have had its gain adjusted upward based on the ratio of'incore to excore power readings determined I, during initial startup testing in November 198 C ______- ___ : ._ _

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  (1) Inter-departmental Misunderstanding The inter-departmental misunderstanding originally took place in late 1984, and again in August 1985 between the Reactor
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Engineering (RE) and I&C group RE personnel removed tho l isolation Smplifier calibrations and provisions to make the J required mections at the AI summing amplifier from Engineering l Surveillance Procedure ESP-ZZ-00006, "Incore-Excore Calibration," I i while assuming that the required calibrations woul' b 4 mplemented ! by I&C Surveillance Procedures ISL-SE-0N41B, ISL-SE-0N42B, 1 ISL-SE-0N43B, and ISL-SE-0N44B, " Power Range Nuclear Instrumentation Axial Flux Difference." The removal of this calibration occurred in November 1984, prior to the initial use ) of these procedures. It was not until 1985 that plant personnel determined that the isolation amplifiers were not being calibrated in the axial flux difference procedure The procedures were modified in 1985 to include the isolat on amplifiers, but the gain on the AI summing amplifier was assumed to be a fixed value and not to be adjusted based on the JU-8000 document. In addition, I&C personnel incorrectly assumed that an input of 2 volts to the function generator corresponded to a AI of 130%. RE personnel questioned I&C in 1985 on the appropriate output voltage (-4 volts at -30% AI) from the Al function generato Past calibrations set the negative AI first breakpoint at -2 volts versus -4 volts. I&C erroneously concluded that the -2 volts was correct because this was the value initially determined i from Westinghouse OTAT startup instructions. However, these instructions were specified by Westinghouse to be used only on initial startup until the incore/excore ratio could be determine The v61tages were to then be adjusted based on the actual ratio measured at the facility rather than continuing to use the initial assumption of 1:1 ratio of incore/excore reading I&C personnel came to their decision based on the changes that would have had to have been made to the various gains of the meter, recorder, and the AI summer. While the gain to the AI summer would have been increased, corresponding decreases would have had to be made to the gains feeding the meter and recorde Based on this perceived incongruity, I&C personnel concluded that the -2 volts that was being used at that time was appropriat During the OTAT calibrations performed in May 1987, no further adjustments could be made to the isolation amplifiers' gain to obtain the required results. I&C therefore made the adjustments to the AI summing amplifier, and requested that the Instrument Setpoint Index (JU-8000) be revised to show that the AI summing amplifier had a variable rather than a fixed gain. During the review of this request, the error in the AI scaling factor was foun _ _ _ __ _ _ _ - - _ _____ _

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e . The licensee determined that the Al function generator should output -4 volts when the Al was -30%. LER 87-012 was subsequently issued and the AI components were properly calibrate (2) JU-8000 Instrument Setpoint Index Error The JU-8000 document stated that the AI summer should have a fixed gain of one. The gain was provided by Westinghouse initial startup documents with a note that this gain may vary depending on the current incore/excore calibration. The fixed gain requirement complicated the scaling issue. This made a-2 volts AI function generator output appear acceptable when compared to initial startup data. The non-conservative setting of the OTAT reactor trip was the result of the incorrect setting of the AI summer gai Based on the incore/excore measurement result of 1:1.8, the licensee decided to set a conservative gain of 2 into the AI summer. In addition, Callaway Modification Package CMP-87-1060 was issued to establish new gain values for OTAT setpoint inputs from AI, and to update the JU-8000 documen (3) Conversion of Percentage Units (PU) to Scaling Values l l Additional confusion regarding the setting of the appropriate AI scaling values came from the conversion of pus to scaling values. Two Westinghouse documents were available to set the gains. One of these documents was the technical manual on the nuclear instrumentation system, which stated that each excore detector should be calibrated to read from 0 to 120 pu The !

other document was the scaling manual for the AI summer and function generator, which stated that each excore read from 1 This difference (2 to 1) supported the theory

0 to 60 pu that the expected function generator output should be -2 volts i , instead of -4 volts for a -30% AI. The AI summer gain was 1 l therefore left at 1 in 1985. I&C personnel Lad compared the I ratio of the detector currents provided by RE during the f quarterly calibrations, and had noted that with the gain j settings as they were the 34 PU difference between top and l bottom currents matched the +30% AI. Since they assumed these numbers were approximately equivalent, they felt no adjustments were warranted to the AI summer gain unit. I&C personnel had not been aware that the Al excore versus incore ratio had been approximately 1.8/1. In addition, by making the assumptions that the PU differences should match the AI, they had mistakenly confused percentage power with percentage units and thought them tc be equivelent when they were not. As part of the licensee's ! corrective actions for this event, a summer gain formula has been l derived that is based on upper and lower neutron detector j currents. The inspector examined this formula and determined ' that it accurstely determines the proper AI sumfner gai ) l l I

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L l I' r , c. Program Review

The inspector reviewed the event for other possible cause l This included 50.59 reviews on procedure changes, training, and personnel qualifications. The licensee was adequately preparing and approving 50.59 reviews on procedurer associated with the AFD even A review of the initial 50.59 evaluations performed for the surveillance. procedure which deleted the AI summer calibration 1 indicated that no safety concern existed, since this activity was 1 to be incorporated in the associated I&C procedures. However, as ' noted above, the calibration was not incorporated, and the original I procedure revision review was completed based on this erroneous assumption. It is recommended that for future procedure revisions which entail incorporation of various steps in some other procedure, both procedure revision packages and the associated 50.59 reviews should be processed as a unit rather than independentl Discussion of the event with plant personnel indicated that the event was not specifically caused by inadequate training. The individuals involved in the event exceeded the professional-technical qualification requirements of Section 4.4 of ANSI /ANS-3.1-1978,

 " Standard for Selection and Training of Personnel for Nuclear Power Plants." The lack of knowledge by personnel responsible for determining the appropriate AI scaling facters appears to have been caysed by misunderstanding of the associated vendor documentatio As such, the training program for these personnel did not correct the problem, but reinforced it by utilizing the same vendor documentatio Based on the above reviews, the inspector concluded that there were no programmatic failures indicated in the training program or conduct ,

of 50.59 evaluations; homver, future 50.59 evaluations which involve moving activities between procedures should be conducted concurrently rather than individuall d. Procedure Review The inspector reviewed the following surveillance procedures: Procedure Number Responsibility Title ESP-ZZ-00006 RE Incore/Excore Calibration ISL-SE-0N41B I&C Power Range ISL-SE-0N428 I&C Nuclear Ins ISL-SE-0N43B I&C Axial Flux ISL-SE-0N44B I&C Difference ISL-BB-0T411 I&C Loop-Temp.; ISL-BB-0T421 I&C Individual Loop ISL-BB-0T431 I&C AT and T-Avg ISL-BB-0T441 I&C

_ _ _ - - o. . l " ! The current version of procedure ESP-ZZ-00006 was used to determine the upper and lower detector currents at -30%, 0%, and +30% AI at 100% reactor power, and to calculate the required AI summer gai , The AI information was used by I&C in the power range axial flux , difference procedures. The AI summer was verified operable in the l loop-temp procedures by input of equal neutron flux signals and verifying the output was zero. As part of the corrective action to this event, the AI summer gain was set at 2. The licensee needs to compare the calculated gain provided by RE upon conducting future ' incore/excore calibrations to ensure that the calculated gain is less than the summer's gain of 2. If this is the case, then the AI input to the OTAT setpoint will be conservative. In addition, the loop-temp procedures used to perform this activity did not reference ESP-ZZ-00006, the procedure performed to determine the calculated gain. The licensee's revision of procedures ISL-BB-0T411, 421, 431, and 441 to include a reference to ESP-ZZ-00006, and to perform a gain comparison between calculated and actual AI summer gain will be tracked as an Open Item (483/87024-01).

The other surveillance procedures reviewed were acceptable and appeared to have no impact on this event. The inspector reviewed the current administrative procedure APA-ZZ-00101, " Preparation, Revision, Approval, and Control of Procedures," in the area of procedure revision development and reviewer qualifications. This procedure had steps requiring performance of a cross-discipline revie The licensee has subsequently proposed additional steps to strengthen APA-ZZ-00101 cross-disciplinary reviews and steps to ensure that procedure requirements that are transferred from one procedure to another are tracked to ensure the requirements are approved in the new procedure prior to deletion from the procedure being revise The inspector concurs with this proposal, which may help prevent the recurrence of inter-departmental misunderstandings during procedure revision The licensee was currently reviewing other inter-departmental procedures to ensure that information transfer was adequately performe e. Technical Specification Applicability The incorrect scaling of the 6I function was a violation of Technical Specification 2.2.1, which required that the reactor trip system instrumentation shall be set consistent with the trip setpoint values shown in Table 2.2-1. The trip setpoint for OTAT was specified in Note 1 of Table 2.2-1, with a maximum allowable value specified in Note 2 of the table. Sections (ii) and (iii) of Note 1 of Table 2.2-1 require that the OTAT trip setpoint be automatically reduced by 1.91% of its value at design thermal power if AI is less than -35%, and automatically reduced by 1.89% of its value at design thermal power if AI is greater than +6%.

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As'noted above, since November 1984, the trip setpoint would not have been. reduced unless AI was~1ess than -70% or greater than

     +12%.' -Therefore,.during the-time period of November 1984 to June 1987, all four channels of the OTAT- trip were improperly set with          ;
    ' respect to.the AI. scaling. factor. Since Note 2 of Table 2.2-1          '
'

states that the maximum trip setpoint shall not exceed the actual value by more than 2%,-the'effect of the AI scaling error was to have the automatic trip setpoint beyond the maximum trip setpoin The action statemerL of TS 2.2.1.b states that with the reactor trip system instrumentation less conservative than the value shown in the allowable values column, either'. adjust the setpoint (which was'not done until discovered in 1987) or declare the channel inoperable and apply the applicable action statement

. requirement of TS 3.3.1.until the channel is restored to operable status with its setpoint adjusted consistent with the trip setpoint value. .TS 3.3.1 specified a limiting condition of operation (LC0)' effectively allowing only one channel of the OTAT trip system to be inoperable whenever the plant was operated in Modes 1 or 2. However, since all four channels were effectively inoperable, TS 3.0.3 would apply which required that the plant be at least in hot shutdown within 12 hour The plant operated throughout the period November 1984 through June 1987 without ever implementing the action statement of the LC This is a violation, Safety Significance During the July 30, 1987 management meeting, licensee representatives presented their conclusions as to the safety significance of the OTAT event- . In addition, a review was conducted of !A operational history of the plant during the period from initial criticality to date. ~ The licensee evaluation determined that, even with the incorrect AI scaling,- the OTAT reactor trip would still have provided core protection to prevent departure from nucleate boiling (DNB).

The AI values recorded on plant instrumentation indicated that the-plant had never operated with an axial flux difference that was greater than +6% or less than -35%, therefore, the AI scaling factor for the trip setpoint would have always been.0, and thus would have never resulted in a reduction of the trip sei. poin The axial offset (AO) envelope was calculated for the as-found AI input to the OTAT trip setpoint and it was compared to the Cycle 2 safety analysis design basis setpoint curve. The actual 0 TAT setpoint was less than the design basis, and thus conservative, for an A0 of less than +17.5%. For an A0 greater than +17.5% to the maximum l expected A0 of +33%, the plant operating setpoint curve was ' non-conservative compared to the design setpoint curve.

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m .. At.the maximum expected A0 value of'+33%, the actual curve is-greater than the design curve.by 5% power. This design curve was predicated on the assumptions of a minimum measured RCS flow- rate rather. than the actual flow rate, and a'. higher power -level i i n tne licensed power level'for the Callaway plan When these .) unservative assumptions were.also taken into consideration and a new A0 design basis setpoint curve was used, the actual OTAT setpoint=was always conservative and would have provided protection over the full range of expected axial offset In ac'dition,' backup protection to prevent DNB was provided b the low pressure and the low reactor coolant flow reactor trip Based on the. inspectors review of the above, the safety significance

of.this event is considered mino >

" Corrective' Actions As a result of this event, several corrective actions were implemented, some of which have already been described above. To correct the initial problem with the AI scaling, the circuitry was-corrected   !

on' June 25, .1987. by a temporary modification. Modification Package

CMP-87-1060 has'been initiated.to permanently implement the change to the scaling calibration' procedures and to update the required design documents. _Several procedure revisions were beir.g implemented to ensure that the calibration steps dropped when ESP-ZZ-00006 was , revised have been included in the appropriate I&C procedure ! Additionally, an independent reviews of ISL-SE-0N418, ON42B, ON43B, ON448, and other I&C surveillance procedures requiring input from other departments or organizations which impact reactor protection scaling were being conducted by the. licensee's Safety Analysis and Reactor Systems Licensing Group. The incident was also discussed with all reactor engineering and I&C personne . Open' Items , ' Open items are matters which have been discussed with the licensee, which will be reviewed further by the inspector, and which involve some action on the part of the NRC or licensee or both. An open item disclosed during this inspection is discussed in Paragraph . Management Meetings July-30, 1987 Management Meeting At the licensce's request, a meeting was held in the Region III' Office on July 30, 1987, (attendees as denoted in Paragraph 1).

Licensee representatives presented background information, a revision

  .to the previously-submitted LER, and a detailed analysis of the results of- their investigation into the event. The contributing causes, corrective 6ctions implemented and proposed, actions to prevent recurrence, and safety significance were included. The slides used in the licensee's presentation are attached to this repor _  -. _

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l Exit Meeting-

  .The. inspector met'with the licensee representatives'(denoted in
  . Paragraph 1) on August 7, 198 The inspector summarized the scope and findings of the inspection.. The licensee' acknowledged-4   .the statements made by the:spector with.rsspect to the Open Item and other noted conce as. The inspector also discussed the likely informational cotaent of the' inspection report with regard to documents or procetoes' reviewed by the. inspector'during;the inspection. Thetlicensee did not-identify any such documents or processes as proprietar Attachment:
 . Slides Used in
  : July 30,1987 Management Meeting
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CALIBRATION DATA SUMMARY TABLE . NIS POWER RANGE CHANNEL 42

TEST DATA FLUX CORE INCORE I*rn- Ia wnv

  ' MAP   POWER'   AO 87-12   99.82   -5.766 24 .66001   '8.224
        - 24 e .87   -9.91~,999 23 .6 87-15   99.83999   -11.975 20 .4 87-16   99.87'   -13.938 23 .6 COMPUTED VALUES FLUX  INCORE   EXCORE IN yn- Iw ony MAP  AFD   AO 87-12   -5.77   -0.98 24 .5 87-13   -8.22   -4.28 24 .1 87-14   -9.91   -5.29 24 .9 G7-15   -11.97   -6.01 23 .3 87-16   -13.94   -7.35 23 a One, = 100 %

) )- PAGE 2 'E ) L ESP-ZZ-OOOO6 REV. 7 5/15/97 _ _ _ _ _ _ - - _ _ _ _ _ - - _ _ _ _ . _ _ _ _ _ _ _ _ _ - . _ _ _ _ _ _ _ _ __ _ _ _ _ . . _ _ _ _ _ _ _ _ _ _ _ _ -

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AFD CALIBRATION VALUES TABLE .

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) .

AFD =-30 % CHANNEL I,ny (ua) Inor (ua) ) N 41 21 .7 N 42 21 N 43 21 .8 N 44 297.~ 282.7 ) AFD = 0 % CHANNEL Irn- (ua) Innr (um) N 41 26 .2 N 42 25 .7 ) N 43 23 .6 N 44 24 .9 AFD = 30 */. ) CHANNEL Irn- (ua) Inor (ua) N 41 '310 22 N 42 29 .9 N 43 70 .3 N 44 29 .2 )

CONFLETED BY =

                / 5/LO[6"I    ,

__ / N8[E/

F E'/IEWED HY J PAGE 7 ) ) ) ESP-fZ-OOOOe REV. 7 5/15/97 - _ _ _ _ _ - _ _ _ _ - _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .

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v t e Inspection Report - Callaway - 1987024
80 \| 81 \| 82 \| 83 \| 84 \| 85 \| 86 \| 87 \| 88 \| 89 \| 90 \| 91 \| 92 \| 93 \| 94 \| 95 \| 96 \| 97 \| 98 \| 99 00 \| 01 \| 02 \| 03 \| 04 \| 05 \| 06 \| 07 \| 08 \| 09 \| 10 \| 11 \| 12 \| 13 \| 14 \| 15 \| 16 \| 17 \| 18 \| 19 \| 20 \| 21 \| 22 \| 23 \| 24 \|
1987 Quarterly Integrated 1Q (0) 2Q (0) 3Q (0) 4Q (0) Assessments Mid Cycle End of Cycle 8(0) 10(0) 11(0) 12(0) 13(0) 14(0) 15(0) 16(0) 17(0) 18(0) 19(0) 20(0) 21(0) 22(0) 23(0) 24(0) 25(0) 27(0) 28(0) 29(0) 30(0) 31(0) 32(0) 33(0) 34(0) 35(0) 36(0) Security Operator Exams Emergency Planning Other

IR 05000483/1987024

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REGION III

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