IR 05000528/1989037
| ML20248G875 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 09/20/1989 |
| From: | Burdoin J, Huey F NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML20248G873 | List: |
| References | |
| 50-528-89-37, 50-529-89-37, 50-530-89-37, NUDOCS 8910110063 | |
| Download: ML20248G875 (7) | |
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U. S. NUCLEAR REGULATORY COMMISSION
REGION V
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! Report Nos. 50-528/89-37, 50-529/89-37, 50-530/89-37-Docket Nos. 50-528, 50-529, 50-530
, License Nos. NPF-41, NPF-51, NPF-74
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Licensee:
Arizona Nuclear Power Project P. O. Box 52034 Phoenix,. Arizona 85072-2034 Facility Name:
Palo Verde Nuclear Generating Station (PVNGS) Units 1, 2 and 3 Inspection Condu
.d. Au ust 7 1989 t rough August 25, 1989 o
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9 /9 Inspector:
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doi'n, Reactor Inspector
. Mte '51gn6d
'. Approved by:
Thak$
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F..R. Huey, Chief,' Engine p _Secf h Date Signed
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Summary:
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p Inspection on August 7, 1989 - August 25, 1989 (Report Nos. 50-528/89-37,
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50-529/89-37, 50-530/89-37)
Areas Inspe"cted:.I An unannounced routine inspection by one regional inspe'ctor
of various' vital areasmand equipment in the plant, and assessment of the licensee l spa : ram for receipt, storage, and handling of emergency diesel generator fud vil and evaluation of the licensee's program for installation and testing of modifications.
Inspection Procedures Nos. 30703, 37828, 71707, e
93702 and TI 2515/100 were used as guidance for the inspection.
Results:
General Conclusion The licensee's actions taken to correct deficiencies resulting from inspection findings were thorough, timely, properly documented, and adequate.
Significant Safety Matters:
None Summary of Violations or Deviations:
None
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Open Items Summary:
One open item was closed and one item left open.
l 8910110063 8905<20
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Persons' Contacted'
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r The below listed technical,and supervisory personnel were among those
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contacted:
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Arizona Nuclear' Power Project (ANPP)
- T.' Bradish, Compliance Supervisor
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M. Brutcher, Mechanical Systems Engineer
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- P. Coffin, Compliance Engineer.
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S. Coppock, I&C Systems Engineer
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.'K. Donaldson, Elec. Designer
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M. Eskinazi,. Acting Supervisor CWD Project
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L A. Hartwig, I&C Systems Engineer L. Henson, Senior Electrical Engineer K.~ Johnson,' Balance of Plant, Systems Engineering Supervisor S. Karimi Compliance. Engineer S. Kesler, Lead Electrical Engineer D. Larkin, Compliance. Engineer t
L. LoDolo, Dies ~el-Generator Elec/I&C Systems Engineer
- W. Marsh,: Plant Director,, Nuclear Production R. Powelli Diesel Generator Fuel, Systems Engineer
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J. Shawver, Chemistry Standards
- T. Shriver, Compliance Manager D. Smyers, Lead Electrical Engineer
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L. Spiers, Supervisor, Inventory Control
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J. Summy, I&C Engineering Supervisor K. Tyree, Chemistry Technician S. Waters, Licensing Engineer
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D.(Withers, Operations Engineer l-The inspector also talked with other licensee personnel during the course of the inspection.
- Attended the Exit Meeting on August 11, 1989.
- Attended the Exit Meeting on August 25, 1989.
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In addition, NRC Resident Inspector attended the August 11, Exit Meeting 2.
Area Inspection'(71707)
An independent inspection was conducted in the Units 1 &.2 Control Buildings and Auxiliary Buildings.
The inspectors examined areas and equipment for debris,' potential hazards, oil and water leakage, and equipment condition,Le.g., oil level, valve position, and electrical
"s connection configuration and cleanliness.
The equipment and areas a
inspected included:
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A.
Two14160/480V:switchgear rooms'(trains A and B).
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"B'-
' four 125 V battery rooms..
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D C.
Four battery equipment rooms.
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^ D. _ Two remote shutdown panel rooms.
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Two diesel generator machine rooms.
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Two diesel generator control rooms.
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. Unit 2 A.
Two 4160/480V switchgear rooms (trains A and B).
B.
Four 125V battery rooms.
C.
Four battery ~ equipment rooms.
D.
Two remote shutdown panel rooms.
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Two diesel generator machine rooms.
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.Two diesel generator control rooms.
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Two auxiliary feedwater. pump rooms.
.H.
Air handling equipment rooms A and B (elev. 74')
Housekeeping'and equipment status appeared to be acceptable.
3.
(Closed) Proper Receipt, Storage, and Handling of Emergency Diesel Generator JDG) Fuel Oil (TI2515/100)
.The inspector examined the licensee's program for receipt, storage and
' handling of Emergency Diesel Generator (EDG) Fuel Oil. The following procedures, preventive maintenance (PM) tasks, surveillance tests and work models were reviewed.
Procedures 74AC-0CY01, Specifications for Bulk Chemicals 74CH-9XC46, Diesel Generator Fuel Oil Receipt and Verification 420P-2DG01 Appendix J, Sampling the day tank PM TASK
L 007931, Remove Accumulated Condensate from the Brattom of Diesel fuel oil storage tank.
~ 061213', Clean and visually inspect tank internals.
Pressure i
Test Tank to 110% of design pressure.
l-Surveillance Tests 31ST-IDF02, Diesel F.O. Storage Tank Cleaning and F.0. System Pressure
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l Testing a
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41ST-1DG01, Diesel. Generator A Test
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. 73ST-1QH01, 60 Day Surveillance-Test of the Diesel Fuel Cathodic Protection (Rectifiers).
' 73ST-1QH02, 12 Month Surveillance Test of the Diesel Fuel Tank Cathodic Protection (System)
74ST-9DF01, Diesel Generator Fuel Oil Surveillance Test
- Work Models 000178 (Service) Diesel Engine Fuel Oil Suction Strainer
' 000184 (Service) Diesel Engine Fuel Oil Discharge Filter
- These Service Work Models were accomplished on "as required" bases.
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' The inspector examined the above documents in detail and sampled completed: surveillance tests and PM Task (s), except for 31ST-1DF02 and PM
- Task'06123 on' ten year cycle, to determine that they were complete, and being accomplished on. time and at>the required frequency.
, The inspector reviewed blanket purchase order No. 10801388 dated February 10, 1989 for the procurement of #2 diesel fuel oil in accordance with specification 74AC-0CY01 (74AC-0ZZ01).
The inspector examined in detail the r'eceipt documentation for six of nine deliveries of fuel oil made
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against this blanket purchase. order to date.
The receiving documentation-was reviewed to verify ccnformance with requirements of the' purchase
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order, i.e. suppliers certification of quality of fuel oil, chemistry certification of specifications for water / sediment, viscosity, and API gravity;.and documentation was also examined to verify quality control receiving inspection, procurement quality engineering review and prn er authorizing signatures and dates.
The receiving documentation appeared to be in order.
The inspector also reviewed blanket purchase order no. 10801381 dated December 22, 1988, for the chemical analysis of new and. stored fuel oil for emergency diesel generators.
The inspector examined the Chemical Analysis Reports for ten different samples for both new and stored fuel
- oil from units 1, 2 and 3.
The samples were shipped to the laboratory promptly after being taken and the analysis reports were normally dated within five to seven days of the date of fuel oil sample shipment.
The fuel oil sample analysis records appeared to be in order.
The inspector examined the licensee's letter to NRR dated December 23, 1988 requesting approval of the following changes to the FSAR which relate two diesel fuel oil sampling tests:
1)
Substitute test ASTM D2276, Particulate Containment in Aviation
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Turbine Fuels for test ASTM D2274, 0xidation Stability of l
Distillate Fuel Oil (Accelerated Method) and 2)
Substitute Test ?STM D4057.81, Manual Sampling of Petroleum and Petroleum Products, for Test ASTM D270-1975 (deleted as an ASTM Standard).
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a The inspector, after coordinating with the NRR staff, determined that the use'of,these two substitute oil sampling tests was acceptabl.e.
The inspector reviewed the licensee's October 8,1987 memorandum closing out NRC Information Notice 87-04 which concluded that because of the redundancy designed into the fuel oil system there is little potential for the fuel starvation problem occurring at Palo Verde.
- The Palo Verde fuel oil system' design includes. redundant strainers (equipped with differential pressure switches) between.the storage and
. day tanks-which alarm.at the local DG control panel, the main annunciator, and the computer.
The engine mounted booster pump redundant-suction strainers and booster pump redundant discharge filters utilize similar differential alarm systems which also sound at the DG control panel, main annunciator, and computer.
The redundancy in the. system allows.for valv_ing spare strainers or filter, and valving out and cleaning the clogged. strainer or filter.
The inspection of the licensee's program for receipt, storage, and handling'of fuel oil responded specifically to the selected issues outlined in Appendix A to the temporary instruction (identified above)
and to requirements of Section C.2 a through h of Reg. Guide 1.137, " Fuel Oil Systems For Standby Diesel Generators." The licensee's. program appears to adequately address all of these issues and requirements.
The inspector concluded that the fuel oil redundant design is adequate and that the licensee's program for receipt, storage, and handling of emergency diesel generator fuel oil is adequately described in
- . operations, maintenance, and test procedures.
The program has been
" properly implemented as evidenced by the documentation of completed
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i periodic surveillance tests and' preventive maintenance tasks.
This temporary instruction is closed.
4.
Installation 'and Testing of Modifications (37828/93702)
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A,pfoblem with Potter & Brumfield relays first reported in LER
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528/88-18-LO/LI'and' reported again in LER 530/89-007-LO/LI were addressed
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Inspection Report
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88-39-identified that as a permanent solution to the problem, the
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next scheduled. outage.
Inspection Report 89-21 specified as a part of
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closing LER 89-007.to review:
1) the licensee's root cause of failure
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b analysis' and 2) the licensee's procurement process for dedicating
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The. status of' Potter & Brumfield relay modifications during this
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inspection period was the installation of the replacement (new) relays in
, Unit 3 was completed; and the installation of the replacement relays in
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E Unit 1, was still in progress.
The followup in this area will be
completed during a future inspection.
Initial failure analysis described in part under LER 88-18, identified
outgasing of electric insulating varnish and neoprene grommets as the
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cause of corrosion of the internal / components which caused binding of'the
roto'r of:the Potter & Brumfield relays.- The licensee with Hi-Rel
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Laboratories and'the relay manufacturer developed new specifications for
materials of internal components and a new process of insulating the
. coils with' epoxy in lieu of; insulating varnish.
The new insulating
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process involved dipping the relay assembly after the coils had been
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mounted on the laminated pole pieces and then placing the entire assembly
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in the oven to' bake the ep' oxy.
The process provided for varnishing and-
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baking the. coils before-they were mounted on the. pole pieces.
The
process h'owever, was not~ practical when insulating with epoxy because
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'whenithe coils.came out of.the oven they were cast rigid with no
flexibility which would allow them to be mounted on the pole pieces.
When.. insulated with varnish (the old method), the coils were pliable
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which facilitated their mounting on the pole pieceF and allowed shaping
the coils to the contour.of the laminated stator core.
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However the new pro' cess of dipping the entire laminated core assembly
with coils mounted on the pole pieces proved to have a major
disadvantage.
When the assembly was dipped, epoxy migrated in between
the laminations of core-and pole pieces.
Later when the relay was placed
in operation and the coil was continuously energized, the epoxy between
the laminations leeched out on to the faces of the pole pieces (Normally
in contact with rotor when engergized), cementing the pole pieces and
rotor together.
Thereby,. preventing the rotor from rotating (operating)
when the relay coil was de energized.
To solve this problem, the
modified relays were returned to the factory where they were rebuilt by.
replacing completely the motor portion of the relay.
This included a new
laminated stator core. a new rotor and new coils.
To manufacture the new
coils with baked epoxy, Potter & Brumfield went back to the original
manufacturing process for varnishing insulated coils.
However, in this
case, because of the rigidity of epoxy baked coils, the jig used for
manufacturing the. coils had to be made to very close tolerances.
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the poles pieces over which the coils had to pass during assembly had to
be machined to closer tolerances.
The new process was successful and the
new motors with epoxy insulated coils were assembled.
The inspector examined reports from Hi-Re1 Laboratories, receiving and
shipping documentation and conferred with the licensee's quality
assurance source inspection section to verify the design and quality of
the new Potter & Brumfield replacement relays.
The manufacturing of the
new relays had 100% QC inspection at the factory by a level II electrical
QC inspector under contract to ANPP from United Engineers.
Dedicating Commercial Grade Electrical Components to Safety Grade Status
The Potter & Brumfield relays and thirty LAMBDA power supplies purchased
for installation in the ESFAS cabinets (eight per unit) were examined to
verify dedicating commercial grade electrical components to safety grade.
The thirty new power supplies were purchased to replace the original
ferro-magnetic power supplies included in the initial NSSS system
installation.
The new LAMBDA power supplies have superior line and load
regulation and the manufacturer of the original power supplies no long
raarkets the ferro-magnetic power supplie %;T g;q
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The review of the documentation for dedicating commercial grade, the
- Potter &.Brumfield relays and LAMBDA power supplies was incomplete at the
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inspection' report.
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.The inspector will also review additional licensee supplied documentation
regarding installation and testing of the Potter.& Brumfield relay
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modification.
This is an open item (50-528/89-37-01).
6.
Exit Meeting (30703).
The inspector conducted exit meetings on August 11.and 25, 1989, with
members of the licensee staff as indicated in paragraph 1.
Duringlthese
meetings, the inspector' summarized the scope of the~ inspection activities
and reviewed the inspection findings as described in this report. -The
licensee acknowledged the concerns identified in the report.
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