ML17342A192
| ML17342A192 | |
| Person / Time | |
|---|---|
| Site: | Turkey Point |
| Issue date: | 09/04/1985 |
| From: | Brewer D, Elrod S, Peebles T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML17342A190 | List: |
| References | |
| 50-250-85-26, 50-251-85-26, IEB-80-12, NUDOCS 8509160086 | |
| Download: ML17342A192 (46) | |
See also: IR 05000250/1985026
Text
UNITED STATES
NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323
Report Nos.: 50-250/85-26
and 50-251/85-26
Licensee:
Power
and Light Company
9250 West Flagler Street
Miami, Florida 33102
Docket Nos.:
50-250
and 50-251
Facility Name:
Turkey Point
3 and
4
License Nos.:
and
Inspection
Conducted:
Ju y 8
ugust
19
1985
Inspectors:
T. A. Peebles,
Seni r Resident
Inspector
S
D.
R.
e
r, Resid
t
nspector
Approved by:
S'tep
n A. Elrod, Section Chief
Division of Reactor Projects
Dat
igned
Da
e Signed
Date Signed
SUMMARY
Scope:
,This routine,
unannounced
inspection entailed
260 direct inspection
hours
at the site, including 67'hours of backshift,
in the areas
of licensee
action
on
previous
inspection
'findings,
licensee
event
reports
( LER),
Inspection
and
Enforcement
Bulletin -(IEB) followup, annual/monthly
surveillance,
maintenance
observations
and
reviews,
operational
safety verification,
engineered
safety
features
(ESF) walkdown, plant events,
and independent
inspection.
Results:
Violations
Failure to meet the requirements
of Technical Specifica-
.tion (TS) 6.8. 1, four examples;
failure to meet
the requirements
of TS 6.8.3;
and failure to meet the requirements
of 10 CFR 50, Appendix B, Criterion XVI.
0
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850905
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REPORT
DETAILS
Persons
Contacted
Licensee
Employees
C.
C.
J.
T.
RJ
~K.
B.
H.
- D
E.
D.
AJ
R.
"R.
AJ
0.
RF
R.
E.
V ~
R.
R.
p.
R.
W.
AJ
J.
L.
- H
M.
R.
R.
R.
4W
T.
J.
RD
'kG
M. Wethy, Vice President-Turkey
Point
J.
Baker, Plant Manager-Nuclear
P. Mendieta,
Services
Manager-Nuclear
D. Grandage,
Operations
Superintendent-Nuclear
A. Finn, Operations
Supervisor
Webb, Operations
Supervisor's
Staff
LE Jones,
Technical
Department Supervisor
A. Abrishami, Inservice Testing
( IST) Supervisor
E. Hartman,
Inservice Inspection (ISI) Supervisor
Tomaszewski,
Plant Engineering Supervisor
A. Suarez,
Technical
Department
Engineer
A. Chancy,
Corporate
Licensing
Arias, Regulation
and Compliance Supervisor
L. Teuteberg,
Regulation
and Compliance
Engineer
Hart, Regulation
and Compliance
Engineer
W. Kappes,
Maintenance
Superintendent-Nuclear
E. Suero, Assistant Superintendent,
Electrical Maintenance
H. Southworth,
Engineering
Department,
Special
Projects
A. Longtemps, Assistant
Superintendent,
Mechanical
Maintenance
F. Hayes, Assistant Superintendent,
Instrument
and Control
( ILC)
Maintenance
A. Kaminskas,
Reactor Engineering
Supervisor
G. Mende,
Reactor
Engineer
E. Garrett,
Plant Security Supervisor
W. Hughes,
Health Physics
(HP) Supervisor
M. Brown, Assistant
Health Physics Supervisor
C. Miller, Training Supervisor
J.
Baum, Assistant Training Supervisor
M. Donis, Site Engineering Supervisor
M. Mobray, Site Mechanical
Engineer
C. Huenniger,
Start-up Superintendent
T. Young, Project Site Manager
J. Crisler, Quality Control
(QC) Supervisor
H. Reinhardt,
Quality Control Inspector
J. Earl, Quality Control Inspector
J. Acosta, Quality Assurance
(QA) Superintendent
Bladow, Quality Assurance
Supervisor
P. Coste, Backfit Quality Assurance
Supervisor
A. Labarraque,
Performance
Enhancement
Program
(PEP)
Manager
W. Hasse,
Safety Engineering
Group Chairman
M. Vaux, Safety Engineering
Group Engineer
f ly
T.
C. Grozan,
Licensing Engineer
~P.
Pace,
Licencing Engineer
G. Traczyk, Fire Protection
Department
~J. Price,
General Office, Plant Support Staff
Other
licensee
employees
contacted
included
construction
craftsmen,
engineers,
technicians,
operators,
mechanics,
electricians
and
security
force members.
NRC Inspectors
"D. Falconer
- H. Ornstein,
"D. Brewer
"Attended exit interview
Exit Interview
The
inspection
scope
and
findings
were
summarized
during
management
interviews
held
throughout
the
reporting
period with the
Plant
Manager-
Nuclear
and selected
members of his staff.
The exit meeting
was
held
on August 9,
1985, with the
persons
noted
in
paragraph
1.
The areas
requiring
management
attention
were
reviewed.
No
new significant
items
were
noted
between
the exit meeting
and the
end of
the inspection period.
The three
items identified as violations were:
Failure to meet the requirements
of TS 6.8. 1, in that the
A and
C auxiliary
(AFW)
pumps
were
not
secured
in
accordance
with
procedures
(paragraph ll); maintenance
was
performed
on
AFW flow control
valve
(FCV)
3-2833 without the
use of
a plant work order
(PWO) (paragraph
8); mainte-
nance activities
were not properly documented
during the
replacement
of
a
reactor
protection
system
test
switch
(paragraph
8);
and
maintenance
procedures
were
" not adequately
implemented
during
work
on
the
A and
B
feedwater flow controllers, resulting in the controllers being wired to the
wrong power supplies
(paragraph
8), (250/85-26-01).
Failure to meet the requirements
of TS 6.8.3,
in that unauthorized
temporary
changes
were
made
to
the
surveillance
procedures
for the
system
(paragraph
7), (250/85-26-02).
Failure to meet the Criterion XVI of 10 CFR 50, Appendix B, in that water in
the
instrument
air
system
adversely
affected
the
operability
of
FCV-3-2833
and the adverse quality condition was not promptly identified and
corrected
(paragraph 8), (250, 251/85-26-03).
Three unresolved
items
(UNR) were identified:
Evaluate
the failure of the
licensee
to adjust
the
B
AFW pump electronic
setpoint after
the
pump
was
observed
to trip repeatedly
on
electronic
without exceeding
the
normal
setpoint value.
Evaluate
the
licensee's
failure to test
the
mechanical
and
electronic
trip setpoints
on
a periodic
basis
(paragraph
7),
(UNR 250,
251/85-26-04).
Evaluate
whether
the
backup to instrument air for the
shoul'd
be tested
by actually operating
the
AFW pumps with the instrument air
system isolated
(paragraph
7),
(UNR 250, 251/85-26-05).
Evaluate
the advisability
of calculating
and rescaling
the interim power
range
nuclear
instrument
currents
so that installed annunciators will not
indicate flux imbalances prior to obtaining post refueling
100 percent
power
physics data
(paragraph
12),
(UNR 250, 251/85-26-06).
An
inspector
followup .item IFI (paragraph
13),
(250,
251/85-26-07)
was
identified concerning
whether
Normal Operating
Procedure
15608. 1,
Loss of
Instrument
Air,
requires
improved
instructions
on mitigation of the
consequences
of a loss of instrument air.
The licensee
did not identify as proprietary
any of the materials
provided
to
or
reviewed
by the
inspectors
during this
inspection.
The
licensee
acknowledged
the findings without dissenting
comments.
Licensee Action on Previous Inspection
Findings (92702)
a.
Monthly update of Performance
Enhancement
Program
The
PEP
was
reviewed
to determine if commitments
were
being
met.
Status
was discussed
with the
PEP
Manager
and with other
members
of
management.
The facility upgrade
project
is
on
schedule.
The contractor
has
continued
pouring concrete
support
columns for the
new administrative
building, with the third floor beginning
to
be
poured.
The
paving
around the Health Physics building has
been finished and the fencing to
change
the radiation control area
has
been
moved.
The Health Physics
staff has
moved into the
new building.
The
schedule
for the
PEP continues to be met within acceptable
limits
and all modifications
have
been cleared
by the Region.
q I'
0
b.
Previously Identified Items
(Closed)
UNR 250/83-40-01,
Reactor
Decay
Heat
Inadequate
Procedure.
The
Off
Normal
Operating
Procedure,
(ONOP)
3208. 1,
Malfunction of
Residual
Heat
Removal
(RHR) System,
was adequately
revised
on June
21,
1985.
Another
procedure
to cover complete
loss of RHR, 3/4-0NOP-050,
Loss of RHR, dated
June
12,
1985,
was issued.
These
two ONOPs coupled
with the
procedure
for operation
of the
system,
3/4-0P-050,
Residual
Heat
Removal
System,
dated
May
29,
1985,
are
adequate
for
operator
guidance
to minimize the
impact of malfunctions of the
system
and to properly
lineup the
system.
The
UNR was
opened
by the
Resident
Inspector
in November
1983
due to inadequate
RHR procedures
that contributed
to
the
system
inoperability
and
temperature
excursion
event of October
1983.
The licensee
had agreed at that time
to
promulgate
a
normal
operating
procedure
governing
system
operations.
(Closed)
IFI 250/84-14-06,
Inverter Transfer
Switch
Maintenance
and
Responsibility.
The
licensee
has
assigned
responsibility
to
the
turbine operator
to assure
that inverter transfer switch maintenance
is
properly performed.
(Open) Violation 250,
251/85-02-02,
Failure
to Test the
System.
The
licensee,
in
response
to
the
notice
of violation,
initially developed
a
Temporary
Operating
Procedure
(TOP 158)
and
subsequently,
a
permanent
Operations
Surveillance
Procedure
(OSP) 075.3,
Backup
System Operability Verification, to
test
the
system.
The
procedures
were
developed
and
implemented to measure
the bleed-down rate of the nitrogen bottles
and
verify that the
low pressure
alarms
functioned;
however,
the licensee
has
not
performed
any testing
that
demonstrates
that
the
system will act as
an adequate
backup supply to the
of instrument air.
A more detailed
discussion
of the discrepancy
is
found in paragraph
7 and relates
to
UNR 250, 251/85-26-05.
4.
Unresolved
Items
Three
unresolved
items were identified during this inspection
(paragraphs
7
and 12).
An unresolved
item is
a matter
about which more information is
required to determine
whether it is acceptable
or may involve a violation or
deviation.
5.
Licensee
Event Report
(LER) Followup (92700)
The following LERs were
reviewed
and closed.
The inspector verified that:
reporting
requirements
had
been
met,
causes
had been identified, corrective
actions
appeared
appropriate,
generic applicability had been considered,
and
the
LER forms were
complete.
A more detailed
review was then performed to
verify that:
the licensee
had
reviewed
the event,
corrective
action
had
been
taken,
no unreviewed
safety
questions
were involved,
and
no violation
of regulations
or TS conditions
had
been identified.
4
C
il
(Closed)
On January
8,
1984,
Unit 3 experienced
a reactor
trip from 30 percent
power.
The root cause
was determined
to be
a spurious
signal
which resulted
in closure of the
A steam
generator
(SG)
FCV.
This occurred while the Maintenance
Department
was troubleshooting
the
control circuit.
The spurious closure of this valve or similar valves
has
not recurred.
(Closed)
On January
8,
1984,
the Unit 3 reactor tripped from
one percent
power and
a safety injection signal
was received.
The operators
were
opening
the
main
steam
isolation
valves
and
were
decreasing
the
differential pressure
across
the valves
by rapidly opening
the associated
steam
atmospheric
dump valve.
This caused
a " high steam line flow" in the
line,
and the associated
cooldown caused
the "low primary average
tempera-
ture
" to complete
the initiation.
The licensee
agrees
that this is not
good operating
practice
and
has
instructed
the operators
to
heat
up
the
secondary
plant before trying to
open
the valves.
No water
was injected
since
the
primary pressure
was
higher
than
the
safety
injection
pump
discharge
pressure.
(Closed)
On January
4,
1984, while performing
a surveillance
on the
AFW system,
the
A and
C
AFW pumps
were started
but did not produce
the required flow.
A unit shutdown per the
TS should
have
been started
due
to their inoperability but
was
not.
This
was
the
subject
of escalated
enforcement
action
and was addressed
in report 250/84-04.
C
(Closed)
On
February
12,
1984,
at
6:38 a.m.,
a
Unit
3
reactor trip occurred
from 100
percent
power.
A reduced
flow
resulted
from the
loss of the
3C
4160 volt bus.
The root cause
was
the
malfunction
of
a differential fault protection
relay
in
the
switchyard which tripped Unit 4.
This event
was
the subject of escalated
enforcement
action
and
was addressed
in report 250/84-09.
(Closed)
On
February
16,
1984,
the Unit 3
and
Unit 4
reactors
tripped from 100 percent
power.
A reduced
flow transient
resulted
from the loss of the
4C 4160 volt bus.
The root cause
was
a jarred
relay
caused
by
a bolt interfering with the
opening of a switchgear
door.
This event
was the subject of escalated
enforcement
action
and was addressed
in report 250/84-09.
(Closed)
On February
23,
1984, while performing
a surveil-
lance
on
the
AFW system,
the
B
pump
was
started
but experienced
flow
osci llations
and
was declared
out-of-ser vice.
Unit 3 was
heating
up the
primary system
and Unit 4's reactor
was critical.
A Unit 4 shutdown per the
TS should
have
been started
due to the inoperability but was not.
This was
the subject of escalated
enforcement
action
and
was
addressed
in report
250/84-09.
liI 'I
Qj
1
(Closed)
On March 23,
1984,
Unit
3 experienced
a turbine
runback from 100 percent to 83 percent
power caused
by nuclear
power range
channel
42B detector
reading
low.
Water
was
found in the cabling.
The
source of water was sealed
and the instrument returned to service.
,This was
discussed
in report 250/84-11.
(Closed)
On April 24,
1984,
a Unit 3 reactor trip occurred
from 100 percent
power.
An operator
was switching
a vital bus inverter
and
de-energized
the
wrong inverter
which
caused
a "rod drop
runback" which
resulted
in a reactor trip on high reactor pressure.
This was discussed
in
report 250/84-14.
(Closed)
On
May 14,
1984,
a Unit
3 reactor trip occurred
from 100 percent
power.
Nuclear
power range
channel
35 power supply failed.
This caused
the vital bus breaker for nuclear instrument rack one to trip,
de-energizing
nuclear
power
range.
channel
41
and
causing
a
"rod
drop
runback".
The source of the failed power
supply was
a ground which has
been
repaired.
(Closed)
On
February
12,
1984,
at
9:45
a.m.,
a Unit
4
reactor trip occurred
from
100 percent
power.
A reduced
flow
transient resulted
from the loss of the'C
4160 volt bus.
The root cause
was the malfunction of an electrical
synchronism
relay which allowed the
erroneous
closure
of
a
de-energized
bus
feeder
breaker
during
the
restoration
of power to Unit 3 following the Unit 3 reactor trip.
This
event
was the subject of escalated
enforcement
action
and
was
addressed
in
report 251/84-09.
Additional information was to be sent in
(Closed)
On
March
7,
1984,
a
spurious
signal
from the
containment
radiation
monitor
caused
the
containment
and
control
room
ventilation systems
to switch to the recirculation
mode.
(Closed)
VOLUNTARY REPORT,
The April 1984, ISI of the
4A SG
nozzle disclosed
a crack 270 degrees
around the nozzle.
A similar
crack
was
found
on
the
4C
SG,
but it extended
only
180 degrees.
Both
nozzles
were
replaced
per plant change/modification
(PC/M)
84-80.
The
nozzle-to-reducer
areas
were
examined
on the
4B
and the 3A, 3B, and
3C
SGs with no evidence of cracking found.
(Closed)
On August 29,
1984, while Unit 4 was at
100 percent
power,
the
4B Intake Cooling Water
was
removed
from service for
a
period in'xcess
of that allowed per the TS.
This event
was the subject of
escalated
enforcement
action
and was addressed
in report 251/84-30.
IE Bulletin Fol lowup (92703)
The inspector discussed
the requirements
of pending
IEBs with the licensee.
Based
on
an analysis of licensee
supplied information and documentation,
the
inspector
closed all action items relating to the following bulletin:
(Closed - Units
3 and 4),
Decay Heat
Removal
System Operability.
The licensee
responded
to the
IEB on June
11,
1980,
indicating that their
only open
item to close out the
IEB was to revise
ONOP 3208. 1, Malfunction
of Residual
Heat
Removal
(RHR)
System,
by June
30,
1980.
The
licensee
improved
ONOP
3208. 1 adequately
on June
21,
1985,
and
has written another
procedure
to cover
complete
loss of
RHR,
3/4-0NOP-050,
Loss of
RHR, dated
June
12,
1985.
These
two off-normal procedures,
coupled with the procedure
for normal
operation
of the
RHR system,
3/4-0P-050,
Residual
Heat
Removal
System,
dated
May 29,
1985,
are adequate
for operator
guidance to minimize
the
impact of malfunctions of the
RHR system
and to properly line
up the
system.
An
UNR (250/83-40-01)
was
opened
by the
resident
inspector
in
November
1983 for the inadequate
RHR procedures
that contributed to the
system inoperability
and the temperature
excursion
event of October
1983.
The
licensee
had
agreed
at that
time to
promulgate
a
normal
operating
procedure
governing
RHR.
That
UNR is discussed
in paragraph
3b of this
report.
Monthly and Annual Su'rvei llance Observation
(61726/61700)
The inspectors
observed
TS required surveillance
testing
and verified: that
the test
procedures
conformed to the requirements
of the
TS, that testing
was performed in accordance
with adequate
procedures,
that test instrumenta-
tion was calibrated,
that limiting conditions for operation
( LCO) were met,
that test results
met acceptance
criteria
and
were
reviewed
by personnel
other
than
the
individual
directing
the
test,
that
deficiencies
were
identified,
as
appropriate,
and
were
properly
reviewed
and
resolved
by
management
personnel
and
that
system
restoration
was
adequate.
For
completed tests,
the inspectors
verified that testing
frequencies
were
met
and that tests
were performed
by qualified individuals.
The inspectors
witnessed/reviewed
portions of the following test activities:
Units 3 and
4 AFW Train
1 Operability Verification
Units 3 and
4 AFW Train
2 Operability Verification
Instrument Air System
Dew point Sampling
AFW Pumps
A,
B and
C Electronic Overspeed
Testing
Unit 4 Reactor
Protection
System
Logic Testing
On July 22,
1985, at 12:40 a.m.,
the
AFW system received
an automatic start
signal
due to
a low level in the
3B SG.
The
A and
C
AFW pumps tripped
on
mechanical
and, thus,
were not immediately available
to supply the
SG.
The
B
pump trip-and-throttle
valve
cycled
closed
because
its
electronic
setpoint
was
exceeded.
The resultant
loss of steam
supply
reduced
the
pump's
rate of rotation allowing the trip-and-throttle
valve to reopen
as the electronic
reset setpoint
was reached.
The
B AFW pump trip-and-throttle valve cycled repeatedly
in this manner.
Between
1:30
a.m.
and 2:30 a.m.
on July 22, the licensee
performed testing
on all three
AFW pumps to establish operability subsequent
to the overspeed
trips.
gA records
of the testing,
~etained
as
requi~ed
by
Operations
Surveillance
Procedure
(OSP)
3-OSP-075. 1,
Train
1
~
~
Operabi
1 ity
Verificati on,
and
3-OSP-075. 2,
Auxi 1 iary
Train
2
Operability Verification, were reviewed
by the inspectors.
Numerous
steps
in
each
procedure
were
found to
have
been
omitted.
The
omissions constituted
changes
to the intent of the procedures
in that the
acceptance
criteria
for
pump
operability
were
modified
to
be
less
restrictive than
was previously acceptable.
Pump discharge
pressure
was not
monitored or recorded.
Checks for noise
and vibration were not made.
The
pumps were run for less
than the required
15 minute interval,
and they were
not verified to
be capable of delivering feedwater at the required rate of
375 gallons
per minute
(gpm) within three
minutes
of initial operation.
Additionally, the procedural
changes
were not approved
by two members of the
plant management
staff,
they were not documented
or reviewed
by the Plant
Nuclear
Safety
Committee
(PNSC),
nor
were
they
approved
by the
Plant
Manager-Nuclear within 14 days,
as required.
TS 6.8.3 requires that temporary
changes
to procedures
only be
made provided
that:
a.
the intent of the o'riginal procedure
is not altered;
b.
the change is approved
by .two members of the plant management
staff, at
least
one
of
whom holds
a
Senior
Operator's
License
on
the
unit
affected;
and
c.
the
change
is
documented,
reviewed
by the
PNSC
and
approved
by the
Plant Manager-Nuclear
within 14 days of implementation.
Failure to comply with the requirements
of
TS 6.8.3 is
a violation.
This
violation applies to Unit 3 only (250/85-26-02).
The licensee
management
was not aware that only modified versions
of the
surveillance
procedures
had
been
performed following the
AFW pump trips of
July 22,
1985.
When
informed of the
discrepancy
they directed that the
tests
be performed
in their entirety.
Since Unit
3
had
been
cooled
down
during that afternoon
the additional testing
was
performed with the
pumps
aligned to Unit 4.
The surveillance
testing
was
observed
by the
Resident
Inspector
and was completed satisfactorily.
The July 22,
1985, electronic overspeed
cycling of the
B AFW pump trip-and-
throttle valve prompted reviews of previous surveillance
tests to determine
the
hi story of the
problem.
During
a previous
surveillance
on June
23,
1985,
the
B AFW pump failed its operability test
because it twice tripped
on
electronic
Consequently,
PWO
8116
was
issued
to resolve
the
problem.
The
pump
was determined
to
be
running
at
5980
revolutions
per
minute
(rpm)
instead
of the
desired
5900
rpm.
The electronic
setpoint
should
have
been
6200
rpm.
The
B
AFW pump governor
was adjusted
such that the turbine rotated
at
5900
rpm.
The
pump
was tested
and it no
longer tripped
on electronic overspeed.
'II
Ap
Discussions
with technical
support personnel
indicated that the
pump was not
demonstrating
large oscillations
in speed.
The
maximum anticipated
speed
change,
during
normal
operation,
is
about
100 rpm.
Consequently,
on
June
23,
1985,
the electronic
for the
B AFM pump could have
been
estimated
to have occurred at
no more than
6080 rpm.
The licensee
did not
perform
this
extrapolation
and
after
the
symptom
had
been
corrected,
a verification of the actual
setpoint
was not performed.
Following the malfunction of the
B AFM pump on July 22,
1985,
the electronic
setpoint
was tested.
The setpoint
was found to be 6066
rpm which
was
134
rpm too low.
Apparently, the electronic
tri.ps
on June
23
and July 22 were
due to an incorrectly adjusted
setpoint.
Discussions
with the licensee
revealed
that their surveillance
program did
not require
the
routine
periodic testing
of either
the
electronic
or
mechanical
setpoints.
The electronic
and
mechanical
setpoints
had last been
checked
in December
1983, following installation of
new governors.
While not
on
a periodic schedule,
the mechanical
setpoints
were subsequently
tested
in 1984 following governor maintenance.
On March
1,
1985,
the
Power Plant
Engineering
Department
recommended
that
both the electronic
and
mechanical
setpoints
be tested
annually
(JPE-PTPO-231).
On March 26,
1985, the Technical
Department
requested
that
the
Procedure
Upgrade
Project
(PUP)
develop the procedures
by December
31,
1985.
As of August
12,
work on the
procedures
had not begun.
Since
the
testing
process
is
not
complicated
and
since
the
Technical
Department did not request
the procedures
in the near future,
a low'priority
was assigned
to the task.
The failure of the licensee
to have
a program requiring periodic testing of
the electronic
and mechanical
setpoints
and the failure of the
licensee,
on
June
23,
1985,
to
address
the
improper
setting
of the
electronic
setpoint
on the
B AFW pump is an
UNR (250,251/85-26-04)
pending additional
review and analysis
by the resident
inspectors.
Early
on July
24,
1985,
the
licensee
returned
Unit,
3 to critical
and
performed
AFM pump testing,
including electronic
testing,
on the
A
and
C
pumps.
Testing
was
observed
by the
Resident
Inspector
and
was
satisfactory
on the
A pump;
the electronic
testing portion
was
satisfactory
on the
C pump.
During this testing,
when the
FCV controllers
were left in the automatic
mode,
the
pump
speed
remained essentially
constant at approximately
5900
rpm
but the
FCVs continuously cycled plus or minus
~~
inch around the
20 percent
open position.
The control board flow indications were rapidly cycling from
0 to
300 gpm,
and
each controller output
was cycling from 0 to 60 percent
demand.
From the control
room it appeared
that the
system
was unstable.
However,
pump speed,
which
has
only local indication',
was stable.
These
unusual
indications
have existed for quite
some time
'E
I
10
The control
room operators
do not feel comfortable with the
system operating
in the automatic
mode.
As
a
standard
practice,
the control
room operators
place the system in manual control
as
soon
as
possible
following automatic
system
initiation.
At the
Resident
Inspector's
request
the
licensee
demonstrated
pump operability in the automatic
mode by running each
pump for
five minutes.
Although the
pumps
did not trip,
the control
room flow
indications
remained erratic
and the licensee
declined
a request
to perform
the full surveillance
procedure
in the automatic
mode.
The
licensee
maintains
that
there
is
no
requirement
that
the
system
be
capable of sustained
automatic operation.
In Inspection
Report
250,251/85-02,
covering
the period of January
1 to
February 2,
1985, Violation 250,251/85-02-02
was issued
because
the licensee
did not demonstrate,
through periodic testing, that the
system
was
capable
of controlling the
As an interim corrective action,
the licensee
developed
TOP 158, Auxiliary Feedwater
System Periodic Nitrogen
Backup Test.
The
TOP is designed
to measure
the bleed-down
rate of the
nitrogen bottles
and to verify that the
low nitrogen
pressure
alarms
are
functional.,
Acceptance criteria require that the bleed-down rate
be
no more
than
50 pounds
per minute and that the low pressure
alarm be received at 500
pounds
per square
inch.
A review of the
revealed
that it does
not verify that the bottled
system
could actually
operate
the
FCVs during
a
simulated
automatic
system
actuation.
The
was only performed with the
AFW pumps
secured.
The
20 percent
open
in manual
control.
Cycling of the valves
through their full range of motion,
as
would occur
during
an automatic
system actuation,
was not required.
The bleed-down rate
obtained
was not representative
of the rates
which would exist if the valves
were operating in the automatic
mode or if the
manual
valve positions
were
frequently adjusted
by the control
room operator.
Measuring the bleed-down
rate
and verifying that it was sufficiently slow to
allow the
timely
replacement
of depleted
bottles
provided only circumstantial
evidence
of
system operability.
Discussions
with licensee
personnel
revealed
that the
AFW system
has at
no
time
been physically operated
with the instrument air system
isolated
and
only nitrogen available to position the
FCVs.
This discrepancy
constitutes
an
UNR (250,251/85-26-05)
pending
an evaluation of the licensee's
AFW system
.
test program.
Maintenance
Observations
(62703
8 62700)
Station maintenance activities of safety-related
systems
and components
were
observed/reviewed
to ascertain
that they were
conducted
in accordance
with
approved
procedures,
regulatory guides,
industry codes
and standards
and in
conformance with TS.
I
Il
)
The following items
were
considered
during this
review,
as appropriate:
that
LCOs were
met while components
or systems
were
removed
from service;
that approvals
were obtained prior to initiating the work; that activities
were
accomplished
using
approved
procedures
and
were
inspected
as
applicable; that procedures
used were adequate
to control the activity; that
troubleshooting
activities
were controlled
and
repair
record
accurately
reflected
what took place; that functional testing and/or calibrations
were
performed
prior to returning
components
or
systems
to service;
that
records
were
maintained;
that activities
were
accomplished
by qualified
personnel;
that
parts
and materials
used
were
properly certified; that
radiological
controls were implemented;
that
QC holdpoints were established
and observed
where required; that fire prevention controls were implemented;
that outside contractor force activities were controlled in accordance
with
the approved
QA program;
and that housekeeping
was actively pur sued.
The following maintenance activities were observed
and/or revie'wed:
Unit 3 AFW FCV-3-2833 repair
Unit 3 and Unit 4 instrument air system repair
Unit 3 reactor
protection
system test switch S-5 replacement
3A and
3B
SG feedwater controller rewiring
Instrument inverter replacement
Reactor protection
system logic contact cleaning
(PWO 7534)
B AFW pump electronic overspeed
setpoint adjustment
AFW FCV-3-2817 positioner calibration
During this inspection
period,
the
licensee
failed to
comply with the
requirements
of
TS 6.8. 1, in the
area of maintenance
activities,
on three
occasions.
On July
14,
1985,, during Unit
3
AFW surveillance
testing,
FCV-3-2833
failed
in the
open
position.
The
valve
was
repaired
without the
issuance
of a
PWO.
Administrative Procedure
(AP) 0190. 19,
dated
May
21,
1985, entitled Control of Maintenance
on Nuclear Safety Related
and
Fire Protection
Equipment,
requires that
a
PWO
be i ssued
for mainte-
nance
activities.
Section
8 of the
procedure
requires
that
and
supervisory
reviews
be performed prior to beginning the maintenance
and
that the activities be thoroughly documented
on the
PWO.
Contrary to the
above,
on July 14,
1985,
maintenance
was performed
on
Unit 3
AFW FCV-3-2833
and
a
PWO was
not issued for the activity.
and supervisory
reviews of the maintenance
were not performed'nd
the
maintenance
was not documented.
b.
On July
30,
1985,
test
switch
S-5
was
replaced
in Unit
3 reactor
protection
rack
41.
0190. 19 requires,
in section
8,
that
the
conduct of maintenance activities
be thoroughly documented
on
a
PWO.
I
12
Contrary to the
above,
on July 30,
1985,
maintenance
activities
were
not thoroughly
documented
during
the
replacement
of switch
S-5
in
reactor protection
system
rack
41 of Unit 3,
in that
erroneous
and
incomplete information was recorded
on
PWO 7546.
The
PWO documentation
section
did not indicate
that wiring changes
had
been
made
on
the
switch prior to its final installation.
At 11:45 p.m.
a
QC Inspector
was contacted
by telephone
and informed of
the
need to replace
the switch.
The replacement
plan was discussed
and
verbal
approval
was
obtained.
A replacement
switch,
part
number
40302-501,
was obtained
from supply and installed.
Subsequent
reactor
protection
system testing indicated that the problem was not completely
corrected
and
switch
S-5
was
not operating
properly.
Troubleshooting
was
resumed
but the
gC Inspector
was not informed that the replacement
of switch
S-5 failed to correct
the
observed
discrepancies.
The
IKC
technician
removed switch S-5
and determined that it contained
normally
closed
rather
than
the
required
normally
open
contacts.
The
technician,
without authorization,
reversed
the contacts
on
S-5
and
reinstalled
the switch.
The entry recorded
on the
PWO states,
"the
correct
switch
was
obtained
and installed,"
which is
an inaccurate
statement.
Switch
S-5
was initially installed
without
independent
verification of the wiring installation.
At the request
of the
NRC
Inspectors,
the verification was performed
and the switch, which is not
listed
as
a
safety-related
component,
was
found
to
be
correctly
installed.
This problem occurred
because
the
gC Department
was not appraised
of
all aspects
of the switch contact discrepancy.
Consequently, it could
not institute
programmatic
protections
to assure
the quality of the
maintenance.
The
18C technician's
actions
were contrary to
numerous
requirements
of
0190. 19.
The
Department
has
issued
noncon-
formances
which
require
the
Naintenance
Department
to
address
the
failure to implement
AP 0190.19.
On August 1,
1985, the Unit 3 reactor tripped due to
a loss of 120 volt
vital instrument
panel
3P08.
Several
hours after the unit stabilized
the
Resident
Inspector verified that
the on-shift reactor
operators
felt
the
plant
had
responded
in
a
manner
consistent
with the
description
found in 3-0NOP-003.8,
Loss of
120 Volt Vital Instrument
Panel
3P08
~
While discussing
the
plant
response,
the
operators
indicated that the
A SG feedwater regulating valve hand/auto controller
was operated
in manual following the loss of power.
Since
3-0NOP-003.8
indicates that the
A SG feedwater regulating valve hand/auto controller
is deenergized
on loss of 3P08,
a review of the apparent
problem was
initiated.
It was determined that the hand/auto
control stations for the
A and
B
feedwater regulating valves were each wired to opposite
power supplies.
Consequently,
the as-built controller wiring was connected
contr ary to
approved
drawings.
The
licensee
determined
that the
crossed
wiring
probably occurred during maintenance
activities
on the controllers
on
13
some
previous
date.
The
date
could
not
be
readily
determined.
Consequently,
the problem existed for an
unknown length of time.
Previously,
on June
13,
1985,
the licensee
had performed testing of the
Unit
3
instrument
power
supplies
to
determine
whether electrical
drawings
were
accurate.
The testing
was
documented
on
PWO
7210.
During the testing,
breaker
7 on power supply
3P08 was opened
and the
B
regulating valve hand/auto controller was observed
to lose
power;
however,
approved
drawings
show that
the
A
regulating valve hand/auto
controller should
have lost
power instead.
The discrepancy
was not detected
by the licensee until after the trip
on August 1,
1985.
Section
5.'1 of ANSI N18.7-1972
and section
9 of Appendix
A of
Regulatory
Guide
1.33
require
that
maintenance
that
can affect the
performance
of safety-related
equipment
shall
be properly
planned
and
performed
in accordance
with written procedures,
documented
instruc-
tions or drawings appropriate
to the circumstances.
Contrary to the
above,
maintenance
procedures
for the
3A and
3B feed-
water regulating valve hand/auto
flow controllers
(CV-2900 and CV-2901,
respectively)
were not adequately
implemented
in that the controllers
were wired to power supplies
other
than those specified in the approved
drawings.
The discrepancy
was corrected
on August 2,
1985.
The
events
discussed
in
items
a through
c occurred
because
the licensee
failed to
comply with
TS 6.8. 1
in that
procedures
were
not adequately
implemented.
Items
a
through
c
document
three
of the
four
examples
constituting
Violation 250/85-26-01.
The other
example
is discussed
in
paragraph
11.
The
following paragraphs
address
a
sequence
of events
and
maintenance
activities concerning
the instrument
air-AFW interface:
d.
At ll:43 p.m.,
on July 21,
1985,
following a Unit 3 reactor trip,
a
low-low level in the
B S/G caused
an auto-start of the
AFM system.
The
AFW system
functioned normally,
and at 11:50 p.m. the reactor control
room operator
placed the normal feedwater
system
in service
and
began
to secure
the
AFW system.
He attempted
to close
FCV-3-2833
(AFW train
2 flow control
valve to the
C SG),
but the valve
was failed in the
full-open position.
The
I&C Department
was notified of the problem.
At 12:40 a.m.,
on July 22,
1985,
a low-low level in the
B
SG occurred
because
the
B main feedwater
bypass
valve,
FCV-3-489, failed to respond
to
demand
signals
from the control
room.
The low-low level
signal
caused
the
AFW system to auto-start.
The
A and
C AFW pumps,
both lined
up to train 1, auto-started
and promptly tripped
on mechanical
over-
speed.
The
B AFW pump, lined up to train 2, auto-started
and cycled
on
electronic
Electronic
cycling resulted
in the
trip-and-throttle valve shutting
when the
pump's turbine
reached
the
setpoint
and
then
opening
as
the turbine
slowed
to the
i
I
tl I
14
reset
setpoint.
The cycling
was repetative
and continued
until the
AFW system
was secured.
The circumstances
surrounding
the mechanical
tripping of the
A and
C
AFW pumps are discussed
in paragraph
11.
The cycling of the
B AFW pump
is discussed
in paragraph
7.
At 4:00 a.m.,
a high level in the
C
SG occurred
because
the
bypass
valve,
FCV-3-499, failed to respond
to
a
r emote
manual
close
signal initiated by the reactor control
room operator.
The high level
signal tripped the operating
main feedwater
pump
and auto-started
the
AFW system.
The
AFW system
responded
normally except for FCV-3-2833,
which had remained full-open since failing ear lier.
At 4:40 a.m.,
a cooldown of Unit 3 was begun.
FCV-3-2833 was still out
of service
TS 3.8 provides
no
LCO or action
statement
when
a unit
with an
AFW problem is operating
below two percent
power.
Since Unit 3
was
subcritical
when
FCV.-3-2833 failed,
no
LCO or action
statement
exi sted
and
a cooldown was
begun
under
TS 3.0. 1.
The transients
of July 22,
1985,
revealed
valve operability di screpan-
cies for AFW train
2 FCV-3-2833,
and both main feedwater
bypass
valves,
FCV-3-489 and FCV-3-499.
In each
case
the valves failed to respond
to
remote positioning signals initiated from the control
room.
The Resident
Inspectors
reviewed
gC records
documenting that FCV-3-2833
and
FCV-3-2832 received
maintenance
after malfunctioning during testing
on July 14,
1985.
The Plant Supervisor's
Log documents that FCY-3-2833
did not operate
properly.
Haintenance
personnel
and
members
of the
Technical
Department staff stated
that
FCV-3-2833
was cleaned
because
it stuck
open.
Following cleaning it still did not fully close until
its positioner
was re-zeroed.
Water
was
found in the
instrument air
supply line.
FCV-3-2832 failed to reposition
in response
to
remote
signals until after its orifice plunger
was exercised
to unblock
an
obstructed
instrument air bleed-off line.
On July 22,
1985,
18C technicians
removed,
cleaned
and recalibrated
the
FCV-3-2833 current-to-pneumatic
controller.
Upon controller reinstalla-
tion, the valve was stroked
and immediately stuck in the
open position.
Investigation
revealed
that water
in the valve's
instrument air line
precluded
proper
valve operation.
The water
was
blown
out of the
instrument air line and
then
the valve
was
stroked
successfully
and
returned to service (reference
PWO 7491).
Early
on July 24,
1985,
the licensee
started
the Unit 3 reactor
and
performed
AFW system
surveillance
testing.
FCV-3-2833
and
FCV-3-2832
failed to reclose at the
end of the A AFW pump testing.
The licensee
determined
that train
1 of the
AFW system
was inoperable
due to the
failure of the valves
and Unit 3 was placed in hot standby.
15
Later
on July 24,
the inspectors
informed maintenance
personnel
that
Unit 4 instrument air dessicant
dryer had
a high humidity alarm and was
not operating
properly.
An evaluation
revealed
that the dryer system
was improperly aligned.
Several
components
were found to be inoperable
and
a
PWO was submitted to address
the discrepancies.
Since
the Unit 4 -instrument air system supplies air to Unit 3 train
2
including
FCY-3-2833,
and
since
the Unit 4 instrument air
dryer
was
observed
,to
be
operating
with unattended
high humidity
alarms,
the licensee
checked
the Unit
4
FCVs for water
in the
instrument air lines.
The instrument air line for one Unit 4 train
1
AFW FCV was found to contain water.
The Unit 4 instrument air system
supplies
both Unit 4 train
1 and Unit 3 train
2
On the afternoon
of July 24,
1985,
the licensee
began to correct the
discrepancies
associated
with the Unit 4 instrument air system.
The
decision
was
made
to
take
local
dew point measurements
at the
FCVs.
I
On July 25,
1985,
the filters which had
been
removed
from each
units'nstrument
air system were observed
to have
been
degraded.
The Unit 4
oil/water separator filter was excessively
wet,
and the dryer outlet
filter had white/gray,
light powder
on it.
The filters
had
been
changed
during quarterly replacement
in June
1985.
The Unit
4 instrument air dryer maintenance
effort resulted
in the
replacement
of the selector
switches,
the cycle timer and the three-way
valve limit switch.
The failed limit switch
had apparently
precluded
energizing
the
drying heaters.
The Unit
4 dryer outlet
dew point
reading
was
determined
to
be
+53
degrees
Fahrenheit
(F).
This
constituted
an
excessively
moisture
ladden air output.
The dryer
outlet dew point should
have
been
on the order of -30 degrees
F.
On the afternoon
of July 25,
1985,
the Unit
3
AFW valve current-to-
pneumatic
converter s
and
positioner
air
lines
were
cleaned.
Some
foreign matter
had
been
cleaned
out of each
valve control
mechanism.
The train
2 valves
had
dew points at their instrument air supply
connections
of +14 degrees
F to +20 degrees
F and the train
1 valve dew
points were +60 degrees
F to +51 degrees
F.
Following a fifteen minute
air system
blowdown, the train
2 valves
had
dew points of +52 degrees
F
to +55 degrees
F.
The dew point values
were indicative of moisture in
the instrument air system.
The
licensee
changed
the
dessicant
in Unit
4 instrument air dryer
because it was
brown
and
had
released
the white/gray
powder
found in
the downstream filters.
These
were indications that the desiccant
may
have lost
a substantial
ability to absorb
moisture.
Some
loose
metal
brackets
were discovered
in the bottom of the
Unit
4 dryer
and
an
evaluation
was begun to determine their significance.
16
Discussions
between
NRC Region II management
and the licensee
resulted
in mutually acceptable
criteria for establishing
and verifying satis-
factory instrument air system operability as follows:
Clean
and
flush
the
controls
for
the
AFW valves
on
Unit 4
(clean/flush/calibrate/retest).
Take
dew
points
on all six Unit
4
AFW valves,
compare
with
acceptance
criteria and evaluate
any discrepancies.
Blowdown low points
and valves of the instrument air system
on
a
systematic
basis
(list locations/length
of time of blowdown /when
done).
Blowdown
AFW valve regulators,
including
main
bypass
valves (list valves/length of time of blowdown /when done).
Take periodic dew point readings
at each dryer outlet and maintain
outlet dew points within acceptable
ranges.
Evaluate
and repai r, as necessary,
the Unit 3 instrument air
system.
The licensee's
evaluation
of the valve failures occurring
on July 22,
1985,
concluded
that water in the instrument air system
had prevented
the
valves
from operating.
The
licensee
was
aware
that
water
was
contained
in the instrument air system but was not aware that the water
would adversely
affect the operation
of the safety-related
When water was observed
in the instrument air supply to FCV-3-2833,
on
July 14,
1985,
the discrepancy
was only symptomatically addressed.
The
lack of management
action at that time was influenced by the informal
and undocumented
nature of the July
14 maintenance
(paragraph S.a.).
10 CFR 50, Appendix B, Criterion XVI, as
implemented
by Florida Power
and Light Topical Quality Assurance
Report (FPL-NQA-100A), Revision 7,
TQR 16.0, Corrective Action, requires,
in part, that measures
shall
be
established
to
assure
that
conditions
adverse
to quality,
such
as
failures,
malfunctions,
deficiencies,
deviations,
defective
material
and
equipment,
and
nonconformances
are
promptly
identified
and
corrected.
Power
and
Light Quality Assurance
Manual, Quality Procedure
(QP)
16. 1,
Revision
8,
delineates
requirements
for assuring
that
conditions
adverse
to quality are corrected.
0190. 13,
dated
May
21,
1985,
entitled
Corrective
Action for
Conditions
Adverse to Quality, itemizes the mechanisms
by which condi-
tions
adverse
to
quality
are
promptly
identified,
tracked
and
corrected.
~
C
1'
17
Contrary to the
above,
the licensee
failed to establish
measures
to
assure
that conditions
adverse
to quality were promptly identified and
corrected,
in that the licensee's
corrective action program
was imple-
mented in a manner
which allowed
symptom correction without requiring
the identification, evaluation
and correction of the
source
problem.
Consequently,
on July 14,
1985,
and again
on July 22,
1985,
water
was
drained
from the
instrument air
supply line for
AFW FCV-3-2833
to
restore
valve operability while no effort was
made to locate,
evaluate
or eliminate
the
source
of the water.
Failure to prevent- water from
entering
the instrument air system
resulted
in
an additional
malfunc-
tion of FCV-3-2833
on July 24,
1985.
The licensee
did not address
the
degraded
status of the instrument air dryers
and heaters until 10 days
after
the air system
was
known to contain water.
By that time
FCV-3-2833
had failed on three
separate
occasions.
The failure
to
meet
the
requirements
of
Criterion XVI is
a Violation 250,251/85-26-03.
9.
Operational
Safety Verification (71707)
The inspectors
observed
control
room operations,
reviewed applicable
logs,
conducted
discussions
with control
room operators,
observed shift turnovers
and confirmed operability of instrumentation.
The inspectors
verified the
operability
of selected
emergency
systems,
verified that maintenance
work
orders
had been
submitted
as required
and verified that followup and priori-
tization of work was accomplished.
The inspectors
reviewed tagout
records,
verified compliance
with
TS
LCOs
and verified the
return
to service of
affected
components.
By observation
and direct
interviews,
verification
was
made
that
the
physical security plan was being implemented.
Plant housekeeping/cleanliness
conditions
and implementation of radiological
controls were observed.
Tours of the intake structure
and diesel,
auxiliary, control
and turbine
buildings
were
conducted
to
observe
plant equipment
conditions
including
potential fire hazards,
fluid leaks
and excessive
vibrations.
The
inspectors
walked
down
accessible
portions
of the following safety-
related
systems
on Unit
3
and
Unit
4 to verify operability
and proper
valve/switch alignment:
Emergency diesel
generators
Component cooling water
4160 volt and 480 volt switchgear
Radiological
waste processing
and storage
Control
room vertical panels
High head safety injection
18
Containment
spray
system
120 volt ac inverters
Battery power supplies
Spent fuel storage
Charging
pumps
No violations or deviations
were identified.
10.
Engineered
Safety Features
Walkdown (71710)
The inspector verified operability of'he
AFW system,
which is
common to
Units
3
and 4,
by performing
a complete
walkdown of the accessible
portion
of the
system.
The
following items
were
specifically
reviewed
and/or
observed
as appropriate:
a.
that the licensee's
system lineup procedures
matched plant drawings
and
the as-built configuration;
b.
that the
equipment
conditions
were satisfactory
and
items that might
degrade
performance
were identified
and evaluated
(e.g.
hangers
and
supports
were operable,
housekeeping
was adequate);
c.
that instrumentation
was properly valved-in
and functioning
and that
calibration dates
were not exceeded;
d.
that
valves
were
in proper position,
breaker
alignment
was correct,
power was available,
and valves were locked/lockwired
as required;
e.
that local
and remote position indications were in agreement
and remote
instrumentation
was functional;
and
f.
that
breakers
and
instrumentation
cabinets
were
free of
damage
and
interference.
During the
walkdown of the
AFW system,
the following discrepancies
were
identified:
g.
Numerous
found to
have
instrument air
leaks
along the
upper cylinder housing.
PWOs
were written documenting
the discrepan-
cies.
The
li'censee
has
begun
an evaluation
of the
leakage
and its
effects
on valve operability.
Recent testing
revealed
no diminished
valve control capabilities
due to instrument air leakage.
h.
A broken
connector
pin was found on the positioner for Unit 3 train
1
valve 2816.
The pin was promptly .replaced.
The connector
pins
on all
12 Unit 3
and Unit 4
FCV positioners
lacked
grease.
While
no
specific
preventive
maintenance
document
requires
pin greasing,
the valve technical
manual
states
that each pin
should
be greased
upon installation.
The licensee
plans to keep these
pins greased
in the future to help preclude binding.
~'
I,
19
j.
Several
FCV positioner
arms
were
improperly aligned
causing
the
arms to scrape their associated
stem lifting arms.
While binding had
apparently
not
occurred,
visual
evidence
of physical
contact
was
present.
The licensee
has
issued
PWOs to align the positioner
arms in
parallel with the
stem lifting arms.
When informed of these discrepancies
the licensee initiated prompt
corrective action.
No violations or deviations
were identified.
Plant Events
(93702)
An independent
review was conducted of the following events.
On July 16,
1985,
a subcritical trip of the Unit 3 reactor occurred
due to
the loss of the
3C vital instrument
bus inverter.
The loss
de-energ'ized
source
range
nuclear
instrument
N-31 causing
a spurious
source
range
high
flux trip.
Shutdown
control
rod banks
A and
B automatically
entered
the
core.
Control rod banks
A through
D were already fully inserted at the time
of the trip.
Fuse
F-6 was replaced
and the inverter was returned to standby
service.
The licensee
is currently expediting
the
replacement
of all
12
inverters with a newer,
more reliable model.
On July
17,
1985,
the Unit 4 reactor tripped from 100 percent
power due to
the loss of the
4D inverter.
A current limiting circuit was
found to have
failed.
The circuit was replaced
and the inverter was restored
to service.
The failure of vital instrument
inverters
is
recognized
as
a repetative
problem.
The inverter s are being replaced
on
an expedited
schedule.
On July 21,
1985, the Unit 3 reactor
tripped from 100 percent
power due to a
spurious
protection
relay actuation.
The
unexpected
relay
actuation
was
attributed to
a lightning strike
near the Unit 3 turbine deck.
During the
resultant transient,
the
AFW system
and the
main feedwater
system did not
respond
properly,
as
discussed
in
paragraphs
6
and
7,
respectively.
Following the first initiation of the
AFW system the
A and
C AFW pumps were
improperly
secured.
The
pumps
were
secured
using
procedure
3-OSP-075. 1,
Train
1 Operability Verification.
Sections
7. 1
and 7.2
of the
procedure
specify that -the trip-and-throttle valve for each
pump be
open prior to exercising
the governor oil knob.
On July 22,
1985,
shortly
after 12:00
am, the
A and
C AFW pump governor oil knobs were exercised prior
to opening
the trip-and-throttle valve for each
pump.
Subsequently,
when
the trip-and-throttle
valves
were
opened,
each
governor
became
misadjusted
due
to additional
pump rotation.
Consequently,
the
A and
C
pumps
tripped
on mechanical
when next called
upon to operate.
Failure to
secure
the
A and
C
AFW pumps in accordance
with procedures
is an example of
Violation 250/85-26-01.
Additional examples
are discussed
in paragraph
8.
On July 24,
1985, the Unit 3 reactor
was
shutdown
due to the failure of AFW
FCV-3-2833
and
FCV-3-2832 to operate
properly.
Water in the instrument air
system
was
found to have contributed to the degraded
status of the valves.
20
The repair of the instrument air
system
and the
in
paragraphs
7 and 8.
On July
26,
1985,
preparations
were
begun
to
again
shut
down Unit
3
following the failure of
AFW FCV-3-2817 to pass
an operability test.
The
valve positioner
was adjusted
and the valve was tested satisfactorily prior
to the reactor being shut
down.
Preparations
to shut
down the reactor
were
terminated.
On July 29,
1985,
the Unit 3 reactor tripped from 100 percent
power due to
dirty relay contacts
in the reactor protection
system cabinets.
The
power
range
nuclear
instrument relay contacts
for high flux were cleaned.
While
no specific dirty relay could be identified, additional
system testing
led
the
PNSC to conclude that
a dirty relay contact existed
and contributed to
the trip.
On August
1,
1985,
the Unit 3 reactor tripped from 32 percent
power due to
the failure of the
B spare
inverter.
Several circuit cards
were
replaced
due
to failed
components.
The inverter
was
returned
to
service.
The
replacement
of the inverters is progressing
on
an expedited
schedule.
12.
Independent
Inspection
During the report
period the inspectors
routinely attended
meetings
with
licensee
management
and monitored shift turnovers
between shift supervisors
(Plant
Supervisor-Nuclear
[PSN]), shift
foremen
(Nuclear
Watch
Engineers
[NWE]) and
l=icensed control
room operators
(CRO).
These
meetings
provided
a
daily status
of plant operating
and testing activities in progress
as well
as
a discussion
of significant
problems
or
incidents.
Based
on
these
discussions,
the
inspectors
reviewed
potential
problem
areas
to indepen-
dently assess
their importance
to safety,
the
proposed
solutions,
improve-
ment
and
progress,
and
adequacy
of corrective
actions.
The
inspector's
reviews
of these
matters
were
not restricted
to the
defined
inspection
program.
Independent
inspection
efforts
were
conducted
in the following
areas:
Axial flux difference off-normal procedures
quadrant
power tilt off-normal procedures
From July
26 through
29,
1985,
Unit
3 control
room annunciators
indicated
that the allowed axial flux band of five percent
was being exceeded.
The
labeled
Axial Flux .> five percent
and Axial Flux
> five
percent
> one
hour,
are controlled
by the digital data
processing
system
(DDPS).
The annunciators
were considered
out of service
by the
CROs because
the
DDPS was
known to not have the correct axial flux limits installed.
The
correct limits were
promulgated
on
June
12,
1985.
Due to
an oversight,
these
limits were not installed in the
DDPS axial flux program until after
the
Unit
3
reactor
was
operated
at
power.
CROs
compensated
for the
erroneously
alarming
by recording
indicated
axial flux as
required
by TS 3.2.8
and
comparing
the values
to the correct limits.
The
installation of the correct axial flux limits in the
DDPS takes only a short
l
3,,
g
21
period of time.
Failure to install the limits resulted in the annunciators
being
needlessly
out of service.
The
problem
was corrected
on August 1,
1985.
Between
August
4
and
8,
1985,
the
upper
and
lower quadrant
power tilt
were
alarmed
in the
Unit
3 control
room.
The
alarms
were
considered
erroneous
because
the power range nuclear instrument currents
had
not been adjusted
to reflect the results of post refueling physics testing.
The
licensee
delayed
the calculation
of the correct
currents
until
100
percent
power, equilibrium xenon flux maps were obtained.
Consequently,
the
power
range nuclear instruments
were providing incorrect radial flux outputs
between
August
4
and 8,
1985.
The licensee
performed flux maps at 30,
50
and
75 percent
power prior to August 4,
and these
maps indicated that there
was not an actual flux imbalance
in either the axial or radial directions.
t
It may be possible to extrapolate
approximate
power range nuclear
instrument
currents
from the lower power flux maps.
The resultant interim values would
represent
a
more accurate
approximation of the
necessary
currents
than is
obtained
by using
the currents
from the pre-refueling
core.
The
interim
values
could
be accurate
enough
to prevent the unnecessary
alarming of the
axial
and radial
alarm circuitry prior
to
completing
the
100
percent
equi librium xenon flux calculations.
The failure of the licensee
to
use
interim currents
to preclude
unnecessary
flux alarms is
an
UNR (250,251/
85-26-06)
pending
further evaluation
of the licensee's
low power physics
testing
program.
13.
Office of Analysis and Evaluation of Operational
Data
(AEOD) Visit
From August
6 to
9,
1985,
a representative
of the Office of the
accompanied
by a Region II inspector
conducted
a special
team site visit to
gather
information
on
the facts
and
circumstances
surrounding
the
malfunction
which occurred
on July 22,
1985.
Details of this event
are
described
elsewhere
in this report.
The
team
focused its efforts
on the
trips which affected
the operability of the
AFW pumps
and
the
degradation
of the instrument air system
which affected
the operability of
safety-related
plant
components.
Information obtained
by the
team will be
utilized to develop
AEOD case
studies
of instrument air
systems
and over-
speed trips of turbine driven pumps.
One
area
of concern
was identified by the
team for subsequent
inspection
followup.
Normal Operating
Procedure
(NOP)
15608. 1,
Loss of Instrument Air,
provides
the operator with instructions
to
be followed in the event of
a
loss of instrument air.
The general
methodology of the procedure
directs
the operator
to restore
instrument air header
pressure
by alternate
methods.
The procedure
does
not provide
adequate
instructions
for the
operations
necessary
to mitigate the
consequences
of a loss of instrument air and the
impact of this transient
on plant components,
i . e.,
no list of affected
components
and their failure modes is provided.
a
-c
22
The licensee
acknowledged
the above concern
and stated that
an evaluation of
NOP 15608. 1 would be conducted to determine if improvements
to the procedure
are
necessary.
Review of the
licensee's
efforts
in this
area will be
identified as
an IFI (250, 251/85-26-07).