ML17305A904

Describes Current Status & Provides Description of Actions Taken to Ensure Continued High Reliability of Emergency Lighting Sys,Per Insp Repts 50-528/90-02,50-529/90-02 & 50-530/90-02.Emergency Lights Mfg by Emergi-Lite

ML17305A904
Person / Time
Site:	Palo Verde
Issue date:	06/19/1990
From:	James M. Levine ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR
To:	Martin J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
References
161-03288-WFC-R, 161-3288-WFC-R, NUDOCS 9006290304
Download: ML17305A904 (44)

Text

ACCELERATED DISTRIBUTION DEMONSTPATION SYSTEM REGULATORY INFORMATION DISTRIBUTION SYSTEM (RIDS)

ACCESSION NBR:900 6290304 DOC.DATE: 90/06/19 NOTARIZED: NO DOCKET FACIL:STN-50-528 Palo Verde Nuclear Station, Unit 1, Arizona Publi 05000528 STN-50-529 Palo Verde Nuclear Station, Unit 2, Arizona Publi 05000529 STN-50-530 Palo Verde Nuclear Station, Unit 3, Arizona Publi 05000530 AUTH. NAME AUTHOR AFFILIATION LEVINE,J.M. Arizona Public Service Co. (formerly Arizona Nuclear Power RECIP.NAME RECIPIENT AFFILIATION MARTIN,J.B. Region 5, Ofc of the Director

SUBJECT:

Describes current status & provides description of actions being taken to assure continued high reliability of ELS.

DISTRIBUTION CODE: IE01D COPIES RECEIVED:LTR ENCL SIZE:

TITLE: General (50 Dkt)-Insp Rept/Notice of Violation esponse NOTES: 05000528 Standardized plant. 05000529 Standardized plant.

J 05000530 1

RECIPIENT COPIES RECIPIENT COPIES ID CODE/NAME LTTR ENCL ID CODE/NAME LTTR ENCL PD5 PD 1 .1 PETERSON,S. 1 1 CHAN,T 1 1 INTERNAL: ACRS 2 2 AEOD 1 1 AEOD/DEIIB 1 1 AEOD/TPAD 1 1 DEDRO 1 1 NRR MORI SSEAU f D 1 1 NRR SHANKMAN,S 1 1 NRR/DLPQ/LPEB10 1 1 NRR/DOEA DIR 11 1 1 NRR/DREP/PEPB9D 1 1 NRR/DRIS/DIR 1 1 NRR/DST/DIR 8E2 1 1 NRR/PMAS/ILRB12 1 1 NUDOCS-ABSTRACT 1 1 1 1 OGC/HDS1 1 1 G F 02 1 1 RGN5 FILE 01 1 1 EXTERNAL LPDR 1 1 NRC PDR 1 1 NSIC 1 1 NOTES: 1 1 NOTE TO ALL "RIDS" RECIPIENTS:

PLEASE HELP US TO REDUCE WASTE! CONTACT THE DOCUMENT CONTROL DESK, ROOM P 1-37 (EXT. 20079) TO ELIMINATEYOUR NAME FROM DISTRIBUTION LISTS FOR DOCUMENTS YOU DON'T NEED!

TOTAL NUMBER OF COPIES REQUIRED: LTTR 26 ENCL 26

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. 0 REQ> pcpo HRC REQlog y Arizona Public Service Company le JlJd 20 P.O. BOX 53999 ~ PHOENIX. ARIZONA85072-3999 PH l2 WILLIAMF. CONWAY 161-03288-MFC/RAB EXECUTIVEVICEPAESIDENT NUCLEAR June 19, 1990 Docket Nos. -STN 50-528/529/530 Mr. John B. Martin Regi'onal Administrator, Region V U. S. Nuclear Regulatory Commission 1450 Maria Lane, Suite 210 walnut Creek, CA 94596-5368

Reference:

Letter from NRC to V. F. Conway, dated April 24, 1990.

Subject:

NRC Inspection of Palo Verde Units 1, 2 and 3 - Inspection Report Nos. 50-528, 529, 530/90-02.

Subject:

Palo Verde Nuclear Generating Station (PVNGS)

Units 1, 2 and 3 Emergency Lighting File: 90-019-026; 90-056-026 During the past several days, members of our respective staffs have been discussing the status of emergency lighting at Palo Verde. This letter describes the current status and provides, as attachments, a description of actions being taken to assure continued high reliability of the emergency lighting system and an analysis of certain test data reques'ted by your staff,.

Emer i-Lite Fixtures In April and May 1989, APS performed'a detailed review of emergency lighting, including a walkdown. As a result of the walkdown, APS decided to install additional emergency lights. Some of these lights are required by 10 CFR 50, Appendix R, and APS management elected 'to add the others. The results of the walkdown and the corrective actions are detailed in LER 89-012.

APS installed emergency lights manufactured by Emergi-Lite as an interim measure and scheduled the design and installation of Modular Power Stations (MPS) and light fixtures to replace the Emergi-Lites. The Emergi-Lites offered the advantage of permitting installation in the near term but had the disadvantage of higher maintenance cost. Recognizing these facts,

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'r. John B. Martin

u. S. Nuclear Regulatory 'Commission 161-03288-WFC/RAB June 19, 1990 Page 2 Emergi Lite units were installed in Palo Verde Units 1, 2 6 3, respectively, and tracked as restart items. The Emergi-Lites were tested when installed. Emergi-Lite components which failed to function adequately

. during these tests were replaced or repaired and each of these lights successfully passed'n acceptance test. The acceptance test required the lights to remain illuminated for at least eight hours with the batteries

,maintaining an electrical potential of at least .21 vol'ts. After successfully passing the acceptance test, the lights were placed in service and a regularly scheduled Preventive Maintenance (PM) program was implemented.

During an NRC inspection, in the the first quarter of 1990, questions arose about the adequacy of the Emergi-Lites, as documented in the referenced letter. ,Since then, in response to these NRC questions, APS has:

Accelerated the schedule for installation of the permanent emergency lights, (MPS System) to August 1990, and Increased the PM frequency from quarterly to monthly, and Performed special discharge 'tests o'f the Emergi-Lites.

Within the past two weeks, APS has conducted discharge tests on 26 of the 48 Emergi-Lites installed in Units 1, 2 and 3. Twenty-three of the 26 fixtures passed the discharge test. The three which did not pass remained illuminated for eight hours, but did not meet acceptance criteria for voltage at the end of the test. The results of these tests demonstrate that the Emergi-Lites are operating reliably.

J Li hts Powered from Exide Power Su lies This system, which supplies the control room emergency lighting, is exhibiting reliable performance and the PM program in use is effectively ensuring continued reliability.

Dual-Lite Fixtures These fixtures are located throughout the plant and are exhibiting reliable performance. However, actions will be taken to enhance the existing PM program. These actions include a pilot program in which the PM frequency will be increased from quarterly to monthly in the Turbine, MSSS, and Diesel Generator buildings in Units 1, 2 & 3. The program will gather and trend additional battery performance information (i.e., electrolyte level, and room temperature) over a six-month period. 'This'trend information will be used as a basis for evaluating the need for changes to the currently existing PM program for Dual-Lite fixtures.

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Mr. John B. Martin 161-03288-4'FC/RAB U. S. Nuclear Regulatory Commission June 19, 1990 Page 3 Li hts Powered from Holo hane Power Su lies Based on a recent engineering calculation, a Material Non-Conformance Report (MNCR) has been issued'egarding certain of these MPSs for ambient temperatures at 50'F., (Units 001 and 003 in Palo Verde Units 1 and 3)..

While the MNCR is being resolved, APS has implemented compensatory measures to ensure the operators are able to fulfill their roles in the event of the loss of these lights and to promptly restore essential lighting if it is lost. These measures provide adequate assurance that if a fire occurs prior to resolution of the MNCR the failure or absence of these lights will not adversely affect the ability to achieve safe shutdown.

The present PM program ('i.e., monthly maintenance and semiannual discharge tests) will be continued on the existing and modified Holophane systems to ensure continued reliability. The reliability of this emergency lighting will be increased through implementation of a series of design changes and equipment replacements.

These actions include:

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Holophane Units 001 and 003 in Units 1 & 3 are presently being modified to increase their capacity and reliability.'his work will be completed in Unit 1 prior to entry into Mode 2 in the current startup and is expected to be completed by June 20; 1990, in Unit 3.

An historical review of Holophane Units 002 and 004 in Units 1 and 3 has been completed to assess the present reliability of these lighting units. The results of this analysis, as described in Attachment 1, demonstrate that these Units are reliable. In addition, the units will be modified to further increase their capacity and reliability. The schedule for these modifications is contingent on delivery of material, and is currently expected to be completed by the end of September 1990.

Holophane Units 001, 002, 003 and 004 in Unit 2 will be modified to increase their capacity and reliability. Initially, higher capacity batteries will be installed in Units .001, 002, 003 and 004 prior to Mode 2 entry. The replacement of inverters in all four units is expected to be completed by the end of October 1990, contingent on material delivery.

APS has also been conducting a detailed review of the Spurious Actuation Analysis. APS has initiated a Corrective Action Report, which has been discussed with your staff, to further evaluate the Spurious Actuation Analysis. We have also implemented compensatory measures, as necessary, for the identified deficiencies. summarizes the status and corrective actions to be implemented on Emergency Lighting and was provided to R. Huey, of your staff, on June 15, 1990.

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Mr. John B. Martin 161-03288-WFC/RAB U. S. Nuclear Regulatory Commission June 19, 1990 Page 4 Based on the information described above, and presented in greater detail to members of your staff during recent inspections APS has concluded that the emergency lighting in Palo Verde Units 1,. 2 and 3 wil'1 function as required.

If you have any questions, .please call R. A. Bernier at (602) 340-4295.

Sincerely,

,WFC/RAB/ca cc: Document Control Desk D. Coe T. L. Chan S'. R. Peterson A. H. Gutterman A. CD Gehr

4i I+I ATTACHMENT 1 ii ~ ~

UNIT 1 AND 3 HOLOPHANE RELIABILITY EVALUATION An evaluation has been performed of the Holophane Modular Power Stations (MPS)

QBN-002 and QBN-004 in Units 1 and 3 to assess their ability to provide reliable lighting should they be called upon to do so.'his evaluation was performed by reviewing the condition and present age of the equipment, the results of the most recent eight hour discharge test, and the history of component failures for these MPSs ~ This evaluation is summarized in this attachment along with a brief description of the equipment and the maintenance program that is currently in place.

DESCRIPTION OF HOLOPHANE MODULAR AC POWER STATION The Holophane Power Station is made up of: a charger, eight batteries, an inverter, an automatic transfer switch, and a voltage control disconnect., The MPS is designed to supply power to emergency fluorescent lighting for a minimum of eight hours. The MPS automatically transfers to battery power will if facility power is lost and transfer back to facility power when restored.

The MPS consists of eight maintenance 'free Wet Cell or Gel Cell batteries (12 volt), in four sets of two batteries in serie's (24 volts) and a charger which maintains the batteries at a float voltage of 27.6 VDC to 28.2 VDC. The MPS also has an adjustable voltage control disconnect which will disconnect the batteries from the load at approximately 70%. This prevents the batteries from operating in a deep discharge condition.

The current loads and the available capacity for each of the Holophane MPSs is summarized in the table below:

UNIT 1 UNIT 3 Load MPS Load MPS (Watts) Capacity (%) (Watts) Capacity (%)

QBN-002 700 122% 700 119%

QBN-004 400 135% 400 197%

It should be noted that the minimum margin available in these units is 19%. The available capacity was calculated using a conservative inverter efficiency and a conservative temperature derating factor.

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The following table presents the dates when the batteries were last replaced in each of the MPSs and the date of the most recent .eight hour discharge test.

Figure 1 presents the results of each of these tests.

UNIT 1 Date Batteries Were Date of Last Successful Last Replaced 8 Hour Discharge QBN-002 5-90 5-90 QBN-004 5-90 5-90 UNIT 3 Date Batteries Were Date of Last Successful Last Replaced 8 Hour Discharge QBN-002 5-88 4-90 QBN-004 8-88 2-90 HOLOPHANE PM PROGRAM The Preventive Maintenance (PM) program for the Holophane MPS provides i'nstructions for the inspection, maintenance, and testing of the MPS. There are two PM tasks, a monthly PM task and a 24 week, eight hour discharge PM.

The monthly PM tasks are performed to ensure operability of .the MPS. The monthly task consist of the following:

1) Inspect battery for electrolyte leakage.

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2) Inspect battery for corrosion, arcing or other significant degradation.

3) Inspect battery for adequate "no-oxide" grease on terminal and connectors.

4) -Obtain and record battery 'bank float voltage, adjustments are made as required to maintain system operability.

5) Obtain and record open-circuit individual battery voltage.

6) Obtain and record the interior temperature of the battery cabinet.

7) Verify indication lights on front face of cabinet.

i' The discharge test PM tasks are performed on a planned 24 week interval to verify the eight hour discharge capability of the MPS. The tasks consist of the following:

1) Inspect battery for electrolyte leakage.

2) Inspect battery for corrosion, arcing or other significant degradation.

3) Inspect battery for adequate "no-oxide" grease on terminal and connectors.

4) Obtain and record battery bank float voltage, no adj ustment is allowed without an amendment or work request.

5) Perform the eight hour discharge test, recording battery bank terminal voltage every 30 minutes,and verifying that fixtures are illuminated.

6) After completion of the eight hour discharge test, recharge the battery for 24.hours, open circuit the battery for 30 minutes, obtain and record the open circuit individual battery voltage

7) Obtain and record the interior temperature of the battery cabinet.

8) Verify indication lights on front face of cabinet.

FAILURE DATA REVIEW A total of thirteen component failures occurred in the four MPSs in the period of January 1988 through May 1990. These were reviewed to determine if the specific component failure would have resulted in loss of the capability of the lights to burn for eight hours following the loss of facility power. Of the 13 component failures, four resulted in actual loss of lighting capability. This data is presented in a time-line for each of the four MPSs (Figure 2).

The time-line depicts graphically component failures from January 1988 to May 1990. The time-1'ine also shows whether the indicated component failure would have affected the ability of the MPS to meet its eight hour discharge requirements A summary of each of the failures evaluated is provided in Appendix A.

i CONCLUSXON The Holophane Modular Power Stations QBN-002 and QBN-004 in Units 1 and 3 are operating reli:ably at this time and will operate reliably with adequate margin remaining at the time of their replacement, which is expected, to occur by the end of September 1990, contingent upon material delivery.. The review of these MPSs showed that the equipment is in good condition, given the current age of the batteries, none, of which has been in service longer than 25 months, and successful completion of the most recent discharge tests with adequate margin.

The review of the failure d'ata for these four MPSs, from January 1988 to May 1990, showed that four component failures of 13 would have resulted in a failure of the MPS to provide eight hour lighting.

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DISCHARGE TEST HOLOPHANE MPS I

25 24 23 22 21

'0 0 4 TIME 1EQBN002 5/90 'EQBN004 5/90 ~ 3EQBN002 2/90 3EQBN004 4/90 ACCE P TAN CE CRI TE RIA FIGURE I

i' Figure 2 Unit 1 8c 3 Holophane Component Failure Time-line 1988-1990 LEGEND Arrows above line represent failures which would not have affected power station's ability to perform 8-hour discharge test Arrows below line repesent failures which would have affected power station's ability to perform 8- hour discharge test

ig UNlT 1 HOLOPHANE COMPONENT FAILURETIME-LINE Power Station lE-QBN-002 1988 1989 1990 18f27/Is I/7/88 Power Station 1E-QBN-004 1I/I/89 I/IS/88 Figure 2a

~i i UNlT 3 HOLOPHANE COMPONENT FAILURE TIME-LINE Power Station 3E-QBN-002 1988 1989 1990 Power, Station 3E-QBN-004 5/24/89 5/4/90 2/l6/90 Figure 2b

ig APPENDIX A

~ > i HOLOPHANE FAILURE EVALUATION UNIT 1 QBN-002 (CONTROL BLDG.)

DATE: EVALUATION

SUMMARY

1-7-88 Shorted battery, all 8 batteries and charger were replaced. This is a failure of the MPS. Lights would not have, burned 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

12-27-89 One battery was below acceptance voltage. This condition would not have prevented the lights from burning 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />. Battery was replaced.

3-26-90 One battery had a cracked'ost and 1 battery was below acceptance voltage. This condition would not have prevented the lights from burning 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

Both batteries were replaced.

5-14-90'wo 2 good batteries (73 Amp-hr) were repl'aced with 96 Amp-hr batteries. The batteries did not fail.. This condition would not have prevented the lights from burning 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

~ i. i HOLOPHANE FAILURE EVALUATION UNIT 1 QBN-004 (CONTROL BLDG.)

DATE: EVALUATION'UMMARY 1-15-88 Two shorted batteries, the charger and 8 batteries were replaced. This is a failure of the MPS.

Lights would not have burned 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

11-1-89 One battery was below acceptance voltage. 'This condition. would not have prevented the lights from burning 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />. Battery was repl'aced'.

3-2-90 One battery was below acceptance voltage. Thi:s condition would not have prevented the lights from burning 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />. Battery was replaced.

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-HOLOPHANE FAILURE EVALUATION

.UNIT 3

'QBN-002 (CONTROL BLDG.)

DATE: EVALUATION

SUMMARY

9-29-88 Failed display board. 'This condition would not have prevented the lights from:burning for 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

The display board was replaced..

i i HOLOPHANE FAILURE EVALUATION UNIT 3 QBN-004 (AUX. BLDG.)

DATE: EVALUATION

SUMMARY

• 8-29-88 Replaced resistor and transformer on, charging card.

Batteries were also replaced. This was a failure of the MPS. Lights would not have burned 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

5-24-89 Loose connection on display card. This condition would not have prevented the lights from burning for 8 hours.

2-16-90 Failed short circuit detector board. This is a failure of the MPS (short circuit detector board replaced). Lights would not have burned 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

3-3-90 Cracked battery post. This condition would not have prevented- the lights from burning for 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

Battery was replaced.

5-4-90 Loose connection on indicating panel. This condition would not have prevented the lights 'from burning for 8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />.

• This date represents when the failure was corrected in the field (8-29-88).

The Work Order was actually closed and reported (11-21-89) as reported on the FDT.

iy ATTACHMENT 2 i

6/15/90 ACTIONS TO ENSURE RELIABLE OPERATION OF THE EMERGENCY LIGHTING AT PVNGS

l. Emergency Lighting as provided from Exide power supplies.

This system is exhibiting reliable performance and the preventive maintenance program in use is effective to ensure this continued performance.

2. Emergency Lighting as provided from Dual-Lite power supplies.

This system is exhibiting reliable performance and actions will be taken to enhance the existing preventive maintenance program.

These actions include:

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A pilot program which will accelerate PM testing from a quarterly to a monthly basis in the Turbine Building, MSSS Building and Diesel Generator Building for Units 1, 2 & 3. The program will gather and trend'dditional operating information (i.e., electrolyte level, room temperature) over a six-month period.

This trend information will be used as a basis to evaluate changes to the

'existing PM program.

3. Emergency Lighting, as provided from Emergi-Lite power supplies.

The Emergi-Lites are operating reliably and the accelerated (i.e., monthly) preventive maintenance will be continued. Additionally, these emergency lights will be replaced in Units 1, 2 & 3 with a centralized .UPS.

The present schedule is to complete this work by the end of August 1990 based on current material delivery schedules.

4. Emergency Lighting as provided from Holophane power supplies.

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The present PM program (i.e., monthly maintenance and'emiannual discharge tests) will be continued on the existing and modified Holophane systems to ensure continued reliability.

These replacements include:

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Holophane Units 001 and 003 in Units 1 & 3 are presently being modified to increase their capacity and reliability. This work will be completed in Unit 1 prior to Mode 2 in the:current startup and is expected to be completed by June 20, 1990, in Unit 3.

Holophane Units 002 and 004 in Units 1 and 3 will be assessed for present reliability by June 16, 1990. In addition, the units will be modified to increase their capacity and.reliability. This schedule is contingent on delivery of material and is currently expected to be completed by the end of September 1990.

Holophane Units 001, 002, 003 and 004 in Unit 2 will be modified to increase their capacity and reliability. Initially, higher capacity batteries will be installed in these units prior to Mode 2 entry. The replacement of iqyerters in these units is expected to be completed by the end of October 1990, contingent on material delivery.

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