IR 05000528/1989037

Insp Repts 50-528/89-37,50-529/89-37 & 50-530/89-37 on 890807-25.No Violations or Deviations Noted.Major Areas Inspected:Various Vital Areas & Equipment in Plant & Assessment of Licensee Program for Receipt & Storage

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: IR 05000528/1989037 ML20248G871
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 J

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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 ,

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 Inspector: '

o #. 9 /9 doi'n, Reactor Inspector . Mte '51gn6d

'. Approved by: i m

F..R. Huey, Chief,' Engine p _Secf h Thak$

Date Signed

-? ; Summary: W p v .

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Inspection on August 7, 1989 - August 25, 1989 (Report Nos. 50-528/89-37,

• - 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 e and testing of modification Inspection Procedures Nos. 30703, 37828, 71707, 93702 and TI 2515/100 were used as guidance for the inspectio Results:

General Conclusion The licensee's actions taken to correct deficiencies resulting from inspection findings were thorough, timely, properly documented, and adequat 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 ope l

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. DETAILS

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J. Persons' Contacted'

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. 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  !

, #*P. Coffin, Compliance Enginee S. Coppock, I&C Systems Engineer .

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.' Donaldson, Elec. Designer 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

1. W. Marsh,: Plant Director,, Nuclear Production R. Powelli Diesel Generator Fuel, Systems Engineer

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J. Shawver, Chemistry Standards

1. T. Shriver, Compliance Manager

. D. Smyers, Lead Electrical Engineer 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 inspectio * Attended the Exit Meeting on August 11, 198 '

1. Attended the Exit Meeting on August 25, 198 In addition, NRC Resident Inspector attended the August 11, Exit Meeting 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

"s equipment condition,Le.g., oil level, valve position, and electrical connection configuration and cleanlines The equipment and areas a inspected included: - <

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' Two14160/480V:switchgear rooms'(trains A and B).

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. ' four 125 V battery rooms. .

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Four battery equipment room ,

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^ D. _ Two remote shutdown panel room Two diesel generator machine room L Two diesel generator control room '

, . Unit 2 Two 4160/480V switchgear rooms (trains A and B). Four 125V battery room Four battery ~ equipment room Two remote shutdown panel room Two diesel generator machine room .Two diesel generator control room Two auxiliary feedwater. pump room . Air handling equipment rooms A and B (elev. 74')

Housekeeping'and equipment status appeared to be acceptabl . (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 reviewe 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 tan ~ 061213', Clean and visually inspect tank internals. Pressure i

Test Tank to 110% of design pressure.

l-Surveillance Tests

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31ST-IDF02, Diesel F.O. Storage Tank Cleaning and F.0. System Pressure l ,

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Testing a

> 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

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These Service Work Models were accomplished on "as required" base ' 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 frequenc , 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

,- against this blanket purchase. order to date. The receiving documentation-

, was reviewed to verify ccnformance with requirements of the' purchase 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 orde 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 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 orde 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

- 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 acceptab 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 Verd 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 compute The redundancy in the. system allows.for valv_ing spare strainers or filter, and valving out and

cleaning the clogged. strainer or filte 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 requirement 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 '

i periodic surveillance tests and' preventive maintenance tasks. This temporary instruction is close . Installation 'and Testing of Modifications (37828/93702) o o e A A,pfoblem with Potter & Brumfield relays first reported in LER 528/88-18-LO/LI'and' reported again in LER 530/89-007-LO/LI were addressed %

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A- .' i + in inspection reports 50-528/88-39 and 50-528/89-21. Inspection Report

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J iJ 88-39-identified that as a permanent solution to the problem, the [# ,

. licensee planned to replace the relays in each unit during the unit's "

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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

_? f commercial grade' electrical components to safety grade electrical

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. The. status of' Potter & Brumfield relay modifications during this -"

"- " ' inspection period was the installation of the replacement (new) relays in

~r , 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 inspectio Initial failure analysis described in part under LER 88-18, identified outgasing of electric insulating varnish and neoprene grommets as the i

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cause of corrosion of the internal / components which caused binding of'the

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the Potter & Brumfield relays.- The licensee with Hi-Rel b 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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7 process involved dipping the relay assembly after the coils had been

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i mounted on the laminated pole pieces and then placing the entire assembly n, in the oven to' bake the ep' oxy. The process provided for varnishing and-baking the. coils before-they were mounted on the. pole pieces. The

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, process h'owever, was not~ practical when insulating with epoxy because

'whenithe coils.came out of.the oven they were cast rigid with no

flexibility which would allow them to be mounted on the pole piece r . When.. insulated with varnish (the old method), the coils were pliable which facilitated their mounting on the pole pieceF and allowed shaping the coilss to the contour.of the laminated stator cor However the new pro' cess of dipping the entire laminated core assembly with coils mounted on the pole pieces proved to have a major disadvantag 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 togethe 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. Also,-

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 assemble 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 Engineer 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 grad The thirty new power supplies were purchased to replace the original ferro-magnetic power supplies included in the initial NSSS system installatio 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 4 y .t

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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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- conclusion ofcthis' inspection and will be addressed in'a future

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inspection' repor .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). 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 repor .

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