ML18033A777
| ML18033A777 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry |
| Issue date: | 05/19/1989 |
| From: | Carpenter D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML18033A775 | List: |
| References | |
| 50-259-89-11, 50-260-89-11, 50-296-89-11, NUDOCS 8906020273 | |
| Download: ML18033A777 (25) | |
See also: IR 05000259/1989011
Text
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UNITED STATES
NUCLEAR REGULATORY COMMISSION
REGION II
101 MARIETTASTREET, N.W.
ATLANTA,GEORGIA 30323
Report 'Nos.:
50-259/89-11,
50-260/89-11
and 50-296/89-11
Licensee:
Valley Authority
6N 38A Lookout Place,
1101 Market Street
Cha,.tanooga,
TN
37402-2801
Docket Nos.:
50-259,
50-260
and 50-296
License Nos.:
and
Facility Name:
Browns Ferry
1-, 2,
and
3
Inspection
Conducted:
March
1 - April 14,
1989
Inspector.
D.
R. Carpenter,
NRC Site Manager
Accompanied
by:
E. Christnot,
Resident
Inspector
W.Bearden,
Resident
Inspector,
K. Ivey, Resident
Inspector
A.
ohnson
ro ect Engineer
/
Approved by: C':
W.
S. Littl , Section Chief,
Inspection
Programs
TVA Projects Division
ate Signed
ate
Si
ned
SUMMARY
Scope
This routine
resident
inspection
included
the
areas
of operational
safety
verification,
surveillance
observation,
maintenance
observation,
design
deficiencies,
fire
prevention/protection,
cable
deterioration,
reportable
occurrences,
and site management
and organization.
Results
Two violations were identified:
259,
260, 296/89-11-01:
Failure to Satisfy T.S. 3.2.A, paragraph
2
296/89-11-05:
Failure to Satisfy T.S. 4.6.B. l.c, paragraph
2
890b020273
890522
ADOCK 05000259
G
One unresolved
item was identified:
259,
260,
296/89-11-02:
Potential
Failure to Satisfy Single Failure Criteria,
paragraph
5
One inspector followup item was identified:
259,
260, 296/89-11-03:
Deteriorated
GE Cables,
paragraph
7
One non-cited'violation
was identified:
260/89-11-04:
Failure to Follow Special
Operating Instruction,
paragraph
2
The
two violations indicated that the licensee
continues
to have
problems in
adequately
controlling post
maintenance
and surveillance
testing activities.
These
areas
are still considered
weak and need additional
management
attention.
The
problems identified in the non-cited violation regarding following special
operating instructions
need
more attention to ensure
plant work activities are
properly controlled.
0
"Unresolved
items
are
matters
about
which
more
information is required
to
determine
whether they are acceptable
or
may involve violations or deviations.
0
REPORT DETAILS
Persons
Contacted
Licensee
Employees:
0. Kingsley, Jr.,
Senior Vice President,
Nuclear
Power
C.
Fax, Jr.,
Vice President
and Nuclear Technical Director
- J.
Bynum; Vice President,
Nuclear
Power Production
"0. 2eringue,
Site Director
"G. Campbell,
Plant Manager
H. Bounds,
Project Engineer
~J. Hutton, Operations
Superintendent
D. Phillips, Maintenance
Superintendent
"J ~ Swindell, Plant Support Superintendent
- D. Mims, Technical
Services
Supervisor
~0.
Hosmer,
Restart
Test Program
Manager
G. Turner, Site guality Assurance
Manager
- P. Carier, Site Licensing Manager
"J.
Savage,
Compliance Supervisor
A. Sorrell, Site Radiological Control Superintendent
R. Tuttle, Site Security Manager
T. Bradish,
Plant Reporting Section
L. Retzer,
Fire Protection Supervisor
- Attended exit interview
Other
licensee
employees
or contractors
contacted
included
licensed
reactor operators,
auxiliary operators,
craftsmen,
technicians,
and public
safety officers;
and quality assurance,
design,
and engineering
personnel.
NRC Attendees
D. Carpenter,
Site .Manager
E. Christnot,
Resident
Inspector
W. Bearden,
Resident
Inspector
A. Johnson,
Project Engineer
W. Little, Section Chief
Acronyms used throughout this report are listed in the last paragraph.
Operational
Safety Verification (71707)
The
NRC inspectors
were kept informed of the overall plant status
and any
significant safety matters related to plant operations.
Daily di scussions
were held with plant management
and various
members of the plant operating
staff.
The
inspectors
made
routine visits to the
control
rooms.
Inspection
observations
included
instrument
readings,
setpoints
and
recordings;
status
of operating
systems;
status
and alignments
of emergency
standby
0
systems;
onsite
and
offsite
emergency
power
sources
available
for
automatic
operation;
purpose
of temporary
tags
on equipment controls
and
switches;
alarm status;
adherence
to procedures;
adherence
to
limiting conditions
for operations;
nuclear
instruments
operability;
temporary alterations
in effect; daily journals
and logs;
stack monitor
recorder
traces;
and control
room manning.
This inspection activity also
included
numerous
informal discussions, with operators
and supervisors.
General
plant tours
were
conducted.
Portions of the turbine buildings,
each reactor building, and general
plant areas
were visited.
Observations
included
valve
positions
and
system
alignment;
and
hanger
conditions;
containment
isolation
alignments;
instrument
readings;
housekeeping;
proper
power
supply
and breaker
alignments;
radiation
area
controls;
tag
controls
on
equipment;
work activities
in progress;
and
radiation
protection
controls.
Informal
discussions
were
held
with
selected
plant personnel
in their functional areas
during these tours.
Failure
to
Satisfy
Technical
Specification
Compensatory
Action
Statements
1.
On February
25,
1989,
MR A-893734 was issued to troubleshoot
and
repair
the Unit
1 channel
"A" reactor
zone
exhaust
radiation
monitor
( 1-RM-90-142)
due
to test
deficiencies
encountered
during the
performance
of 1-SI-4.2.A. 10,
"Reactor
Building and
Refuel
Floor Ventilation
Radiation
Monitor
Calibration
and
Functional
Test."
The
had
been
stopped
and the maintenance
request
(MR) was written which included the
successful
comple-
tion of the
SI to satisfy
the
post-maintenance
testing
requirements.
The radiation monitor was
removed,
repaired,
and
was reinstalled at 1:00 p.m.,
on February
25,
1989.
Technical
Specification table 3.2.A, note
G requires
the Unit
1
Reactor
Building to
be isolated
and the
Standby
Gas
Treatment
(SBGT)
system
to
be started
when the instrument
channel
which
provides
the
"Reactor
Building Ventilation
High
Radiation
Reactor
Zone"
function is inoperable.
This radiation monitor
performs that function for channel
"A".
During the
performance
of the SI, the
SBGT system trains are initiated and the Unit
1
reactor
zone is isolated until the completion of the test.
At
the time the test deficiency
was identified and the radiation
monitor was
taken
out of service,
these
TS
requirements
were
satisfied
as
a direct result of the performance of the SI.
Once the radiation monitor was reinstalled,
the SI was continued
until 6:05 p.m.,
on February
25,
1989,
when the
was
stopped
due
to lack of coverage
on
the night shift.
At that time,
operators
reset
the
SBGT system trains
and the Unit
1 reactor
zone isolation
as well
as other
equipment
actuated
during the
SI.
The
was started
again
on
February
26,
1989,
at 8:00
a.m.,
and the
TS requirements
were met at 8: 17 a.m.; but the SI
was
stopped at 8:50 a.m.
because
a higher priority SI was
needed
for Unit 2.
Once
again
the
SBGT system
was
shut
down and the
Unit
1 Reactor
Building isolation was reset
when the SI was
stopped.
On
February
28,
1989,
licensee
personnel
identified
that the
PMT (completion of the SI) had not been
completed
and
the radiation monitor.was declared
The compensatory
actions
requi red
by the
TS were reinitiated at
10:20 a.m.,
on
February
28,
1989.
Containment,
filtration,
and controlled release
of postulated
radioactive
releases
are specific functions of secondary
contain-
ment
and
Standby
Gas Treatment
(SBGT).
The ventilation exhaust
radiation monitors provide automatic isolation/acutation
signals
which are
required
for the
secondary
containment
and
SBGT to
perform their functions.
'I
Per
the
TS definition of Secondary
Containment Integrity,
is required to be operable
and:
All the unit reactor
building ventilation
system
required to be closed during accident conditions are either:
1.
Capable
of
being
closed
by
an
reactor
building
ventilation
system
automatic
isolation
system or
2.
Closed
by
a least
one
reactor
building ventilation
system
automatic
isolation
valve deactivated
in the
isolated position.
Therefore,
the
operability
of
and
automatic
secondary
containment
isolation
require
the operability
of the
exhaust
radiation monitors.
TS 3.2.A states
that the instrumentation
required for primary
containment
integrity is
given
in
Table
3.2.A
and
states
that the reactor vessel,
reactor building, main
steam lines,
and
are
also
included.
Table
3.2.A
requires
1
radiation
monitor
channel
for each
of the
two train
systems.
If the
required
number of channels
is
not met for the reactor
zone
exhaust
radiation monitors
then
the
reactor
building
must
be
isolated
and
SBGT started.
1n
summary only one radiation monitor was operable
on the unit
1
r eactor
zone ventilation exhaust for a p'eriod of several
days
following corrective
maintenance
because
the post
maintenance
testing
had not been
performed.
The required
number of operable
radiation
monitor
channels
was
not
met
and
the
compensatory
actions
for this
condition
were
not
maintained
while
the
radiation monitor was inoperable.
4
e
The
failure
to maintain
secondary
containment
and
the
system
trains
in operation
during
the
time period that
the
Unit 1,
channel
"A" reactor
zone
exhaust radiation monitor was
inoperable is considered
a violation of Technical Specification 3.2.A, 3.7.B,
and 3.7.C (Violation 259,
200, 296/89-11-01).
The
licensee
identified
and reported this violation to the
NRC
as
documented
in LER-89006,
issued
March 30,
1989.
An
NRC notice
of .violation (NOV) will be issued,
rather than classifying it as
"licensee
identified" with no
NOV since
the corrective action
did not identify the
steps
being
taken
to
ensure
that
post
maintenance
testing will be completed promptly.
On March 7,
1989,
the licensee identified that
sample
was not performed
as required
by
TS after
the
Unit
3
continuous
conductivity monitor (3-CIT-43-11)
was
removed
from
service
on March 6,
1989 at 9: 15 a.m.
Technical Specification 4.6.B,
"Coolant Chemistry," requires
that
a
sample of reactor
coolant
be analyzed
every
8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> for conductivity and chloride
ion content
when the continuous conductivity monitor is inoper-
able.
On March 7,
1989,
at 6: 15 a.m.,
a
sample
was
taken
for
the
normal surveillance
frequency
and at 7:30 a.m.,
a chemistry
lab technician
reported that the monitor was out of service
and
initiated the
8 hour9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br />
sample
frequency.
The
monitor
was
removed
from
service
for calibration
and
troubleshooting
on March 6,
1989 per
MR 877517.
From
a review
of the
completed
MR package,
the
NRC inspector
noted that
a
TS
time limit was not entered
on the
MR and the working instruc-
tions indicated that
a work impact evaluation
was not required.
The
NRC inspector
also
noted that the
SOS
and Unit
1 operator
logs did "not list the monitor as
being
on
March 6,
1989.
However,
the
"Work
Log
Sheet"
provided
with the
package. stated
that the operator
was notified of the monitor's
removal
and return to service.
The failure to perform
sample analysis within
8 hours9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> following the
removal of the Unit 3 continuous
conduc-
tivity monitor
from service
is
considered
a violation of
Technical Specification 4.6.B. 1.c,
(Violation 296/89-11-05).
Although this violation
was identified
by the
licensee,
the
inspector. did not believe that the licensee's
correction action
to prevent recurrence
was adequate
and
a 'NOV will be issued.
I
From reviews of the control
room logs,
completed MR'ackages,
LREDs,
and associated
incident critiques, it appears
that the errors
were
the result of problems in the planning,
review,
and implementation of
maintenance
activities
and the affected operability requirements
for
safety-related
equipment.
Also, insufficient review,
or
lack of
review,
of the
MR packages
resulted
in neither of the
components
being declared
by operations
personnel.
The
NRC inspec-
tors are concerned
that these
examples
occurred
due to similar causes
and
may be indicative of a generic
problem.
b.
Diesel Generator
Walkdown
The
NRC inspector
walked
down
System
82,
Units
1/2
and
3 Diesel
Generators
during this reporting
per iod using
the following plant
drawings:-
0-15E500-3
Unit
1 and 2,
Key Diagram of Standby
Auxiliary Power System
3-15E500-3
Unit 3,
Key Diagram at Normal
and Standby
Auxiliary Power System
1-47E859-1
Unit
1 and 0,
Flow Diagram Emergency
Equipment Cooling Water
Unit 0,
Flow Diagram Fuel Oil System
c.
Failure to Follow Special
Operating Instruction
On April 5,
1989,
the licensee
discovered that Shutdown
Board
B was
not lined up as required
by a special
operating instruction
(memo
B22
890404
014).
Due to various plant activities, additional
480 volt
loads
were shifted to the
shutdown board, i.e. the
2A 480V shutdown
board
and the
A Diesel Auxiliary Board.
In order to preclude
the
possibility
of
an
overload
condition,
the
special
requirements
in
this special
operating instruction stated that the
1C and
2C
RHR pump
breakers
.were
to
be
racked
out
and disabled.
However, it was
discovered
that the
2C
pump breaker
had
not
been
racked
out.
This item was
evaluated
and determined
by the licensee
as not being
reportable.
The inspector
considers
the action taken
by the licensee
to
be appropriate.
A violation for failure to follow a procedure is
not being cited because
the criteria specified in Section
V.A. of the
Enforcement Policy were satisfied.
This is identified
as
Non-cited Violation
(NCV) 260/89-11-04
for
which
no
response
is required.
The
inspectors will continue
to
monitor licensee activities in this area.
0-47E840-3
The
NRC inspector
noted that during this reporting period,
various
D/Gs for all units
were placed in and out of service to support the
Division I, Division II and Division III outages.
No deficiencies
were noted
as to valve lineups, control availability, and switchboard
availability.
The
components
in all eight
DG rooms
and the valves
directly outside the
rooms were adequately
labeled
and identified to
support operation of the system.
Two
violations
and
one
non-cited
violation
were
identified
in
the
Operational
Safety Verification area.
Surveillance
Observation
(61726)
The
inspectors
observed/reviewed
the
surveillance
instructions
(SI)
procedures
discussed
below.
The inspections
consisted
of a review of the
SIs for technical
adequacy
and
conformance
to TS, verification of test
instrument calibration, observation
of the conduct of the test,
confirma-
tion of proper
removal
from service
and return to service
of the
system,
and
a review of the test data.
The inspectors
also verified that limiting
conditions for operation
were
met, testing
was
accomplished
by qualified
personnel,
and the SIs were completed at the required frequency.
On
February
28,
1989,
the
licensee
discovered
that
an expired
Immediate
Temporary
Change
(ITC)-5 was still in place for O-SI-4.7.B.3.C,
"Standby
Gas
Treatment
System
Train Operability Test."
The
SI demonstrates
the
operability of the
SBGT system trains
by manually starting
each train and
verifying that the fan starts,
the relative humidity heaters
energize,
and
dampers align as required.
The ITC was
issued
to allow the verification
of
the
acceptance
criteria
with
the
trains
already
in operation.
Specifically, it allowed the performer to skip the steps for starting the
trains if they were already
running.
At the time the
ITC was written, the
SBGT system trains were running to satisfy other
TS requirements.
The
ITC was given
an expiration date of February
13,
1989,
and should
have
been
removed
on that date
in accordance
with
SDSP
2. 11,
"Implementation
and
Change
of Site
Procedures
and
Instructions."
The
NRC
inspector
reviewed
copies of the
SI which were
performed daily from February
21,
1989
through
February
24,
1989,
for the
"B" and
"C"
system trains
with the expired
ITC still in place.
In each
performance,
the
SBGT system
trains were not running
and the changes
allowed by the
ITC were not used.
Operability of the trains
was verified in accordance
with the approved
steps.
SDSP 2. 11 requires that
ITCs be
removed
from the affected
procedures
upon
expiration.
If the
system
trains
had
been
running during the
performances
on February
21,
1989 through February
24,
1989, the
ITC steps
could
have
been
used
and
TS surveillance
requirements
could
have
been
missed
due to the performance
of an unapproved
pr'ocedure.
Administrative
controls
are
established
to
require
activities
to
be
performed
in
accordance
with requirements
and strict
implementation
of the controls
ensure that the requirements
are met.
This concern
was discussed
with the
licensee.
No violations or deviations
were identified in the Surveillance
Observa-
tion area.
Maintenance
Observation
(62703)
Plant
maintenance
activities
of
selected
safety-related
systems
and
components
were observed/reviewed
to ascertain
that they were conducted
in
accordance
with requirements.
The following items were considered
during
this review:
the limiting conditions for operations
were
met; activities
were
accomplished
using
approved
procedures;
functional
testing
and/or
calibrations
were
performed prior to returning
components
or systems
to
service;
quality
control
records
were
maintained;
activities
were
accomplished
by qualified
personnel;
parts
and
materials
used
were
properly certified;
proper tagout
clearance
procedures
were
adhered
to;
and
radiological
controls
were
implemented
as
required.
Maintenance
requests
were reviewed to determine
the status of outstanding
jobs and to
assure
that priority was assigned
to safety-related
equipment
maintenance
which might affect plant
safety.
The inspectors
observed/reviewed
the
,following maintenance activities during this report period:
On March 5,
1989, while performing post maintenance
testing
(PMT) on
the
"1/2 A" diesel
generator
(DG) following scheduled
Division I
outage
work,
the
DG automatically
started.
This
occurred
when
maintenance
personnel
misinterpreted
a step
in the instruction
and
tho'ught that the
DG monthly operability test (O-SI-4.9.a. l.a.(A)) was
to
be
performed
as part of the
PMT.
Operations
began
an electrical
lineup checklist in accordance
with the SI and due to the electrical
lineup already
in place
per the
PMT, the
DG received
a start signal
and started
as designed.
Operations
shut
down the
DG and realigned
the manipulated
components
to the positions
they were in prior to
beginning the SI.
The
PMT procedure
was clarified and
completed
as
intended.
The
DG was
tagged
out
and
had not been declared
at the time of the event.
On March 10,
1989,
the inspector
observed
WR 911557 which was written
to
troubleshoot
the
cause
of
the
Unit
3
channel
"A" trip
(half-scram actuation)
which occurred
on March 7,
1989, while the bus
was connected
to its alternate
power source (transformer).
Following
the trip, control
room annunciations
indicated the cause
to be
a loss
of power to the
"A" RPS
bus
~
However, field examination
found the
bus to
be energized
and
none of the circuit protectors (for under-
frequency,
and overvoltage)
were tripped.
The licensee
considered
the
cause
to
be
a fluctuation in the
bus voltage
which
temporarily
made
up the circuit protector logic and then returned to
normal.
The circuit protectors
contain
two time delay relays in the
circuit to trip the bus
and the
system. engineer
stated that there
had
been
problems with the circuit protectors
in the past.
During the
troubleshooting,
the
licensee tried to duplicate perturbations
that
may have
been
seen
on the bus
power supply by starting
a control
bay
chiller.
The results indicated that the voltage drop was observable,
but it did not decrease
to the circuit protector trip setpoints.
The
system
engineer
stated
that the operation
of the circuit protectors
and future problems would continue to be reviewed until
a root cause
and
permanent
correction
could
be established.
The
NRC inspector
noted significant involvement by operations,
system
engineering,
and
maintenance
in
planning
and
conducting
the
troubleshooting
activities.
No discrepancies
were identified.
The
resident
inspectors
followed
licensee
maintenance
activities
associated
with problems
with the Unit
2
Loop II injection
isolation valve,
2-FCV-74-67.
The valve which is. a
24 inch
motor
operated
gate
valve with
a
SMB4T Limitorque actuator
had failed
on
March
28,
1989.
During post modification testing,
the
valve
was
backseated-
and
the
thermal
overload
device
prevented
any further
operation.
The valve
had
apparently
become
backseated
during
the
process
of checking for proper direction of rotation after personnel
had failed to place
the valve position
near
enough
to mid position
prior
to attempting
motor
operation
of the valve.
MR 869976
was
written to disassemble,
inspect
and repair the valve
and actuator.
The valve was disassembled
and
no apparent
damage
was detected.
As
a
precaution,
an
ultrasonic
test
of
the
valve
stem
and
visual
inspection
of the
stem
threads
were
performed
with
no
apparent
defects
found.
After repairs
under
MR 869976 were performed,
MOVATs
testing
on 2-FCV-74-67
was
performed.
During the
MOVATs testing
on
April 5, the limitorque operator
again failed when it was
unable
to
unseat
the valve disc.
MR 916006
was written to again disassemble,
inspect
and
repair
the
valve
and
actuator.
The
actuator
was
partially disassembled
and
cleaned,
but valve disassembly
was not
required.
The
l,icensee
determined
that
the failure
was
due
to
a
compressed
spring pack in the actuator.
The
NRC inspector
determined
from discussions
with licensee
personnel
that evidence of spring pack
degradation
was
indicated
in the thrust
signature
during
MOVATs
testing prior to the failure.
The spring
pack
was replaced,
valve
stem
checked for evidence
of bending
and
damage,
valve stroked to
determine
any damage,
actuator
reassembled
and applicable portions of
MOVATs testing reperformed.
The
licensee
performed
an
engineering
evaluation
to determine if
overstress
or other
damage
occurred
to the
valve during
the
two
events.
During the
evaluation,
TVA contacted
the
and
Crane-Aloyce
companies
to obtain their recommendations
and
comments.
According to the
vendors
292,000
lbs is the
maximum possible thrust
that could
have
been
applied
by the actuator
during
a locked motor
condition.
The
weakest
member,
the
stem threads,
are
expected
to
begin yielding at 384,627 lbs.
No actual thrust higher than
194,000
lbs
was measured
during
MOVATs testing of the valve.
Based
on this,
the licensee
determined
that
no overstress
occurred
and
the
valve
should
be safe to operate.
The
NRC inspector
reviewed
the
work packages
associated
with
869976
and
MR 916006.
The packages
contained
a sufficient amount of
detail
and
guidance
to allow acceptable
accomplishment
of the work
and
the
documentation
supported
that
adequate
post
maintenance
testing
was performed.
The
NRC inspectors
walked
down portions of Hold Order 0-89-183,
and
Caution Order 0-89-145 concerning
RHRSW pump maintenance
and reviewed
the clearance
logs to verify compliance with SDSP-14.9,
"Equipment
Clearance
Procedure."
The
review verified
that
the
clearances
isolated
the
affected
portions
of the
systems
being
tagged;
the
documented
components
were tagged
and in the correct positions;
and
any applicable
TS limiting conditions for operation
were satisfied.
No discrepancies
were identified.
~
~
~
~
e
No violations or deviations
were identified in the Maintenance
Observation
area.
5. 'esign
(37700)
The
NRC inspectors
expressed
concern
about the significant number of
instances
of failure to neet the single failure design criteria that have
been recently identified:
During
a licensee restart test
program review of the 250 Volt Battery
Boards
and the
480 Volt AC Shutdown
Boards that occurred in January
1987,
a system engineer
determined that the loss of 250 Volt Battery
Board
Number
1 would cause
loss of 480 Volt Shutdown
Boards
lA 5 1B
due to load shed signals.
The result of this condition was the loss
of the Division II core spray logic.
This concern
was documented
by
the
NRC as IFI 259,
260, 296/88-04-04.
A design deficiency
was identified during the restart test
program
review by the licensee
when both signal trains for the
standby
gas
treatment
system
logic were found wired
up to the
same
relay which
closes all four dampers
located
in the equipment
bay.
This concern
was documented
by the
NRC as IFI 259,
260, 296/88-05-06
'uring
the recent
review by the
NRC of concerns
associated
with the
seismic affects of the vitrified clay piping in the
RCW system, it
was noted that both redundant'afety
related air conditioning units
associated
with the Unit 2 4KV Shutdown
Board
Rooms would be rendered
due to
a single fai lure of the
common
EECW di scharge
flow
path resulting
in the failure of both divisions of 480 Volt Reactor
MOV Boards.
This design
was
the result
of
a
recent
modification
associated
with
P0956.
Additional detail
is
included
in
NRC
Inspection
Report 259,
260, 296/89-10.
The licensee
recently identified an unanalyzed
condition
on March 22,
1989,
where
the
A,
B,
and
C Diesel
Generators
could
be
overloaded
during the first few minutes of an accident.
This could possibly
occur due to the failure of a single lockout relay which prevents
the
three
motor driven fire
pumps
from starting
during
an
accident
condition including
a loss of coolant accident or a loss of offsite
power.
The single relay is
shared
among
the
three
pump starting
logic circuits.
The fire pumps
are
designed
'to automatically start
on
low fire protection
water pressure
with only one
pump starting
initially.with a second
pump and perhaps
a third pump starting if the
10
first pump is unable to provide adequate
system pressure.
Each fire
pump receives
electrical
power
from
a separate
diesel/shutdown
buss
and
a possibility
exists
that
the
three
affected
diesels
could
successionally
fail
on overload
because
the
respective
fire
pump
motors were not blocked for the first 10 minutes of diesel
loading
as
required.
The fire.
pump
demand
could
be
due
to
actuation
of
non-qualified fire detectors
during
an
accident
condition.
This
issue is documented
in
CARR BFP 890219.
The
NRC inspectors
met with members of licensee
management
and requested
that the licensee
described
the
guidance
relative to detecting
potential
single failure problems that they give their personnel
that perform design
and design
change
reviews,
review of test results,
and in review events.
The licensee
has yet to provide
a satisfactory response'o
this concern.
This potential failure to provide adequate
single fai lure criteria during
the design
process will be
documented
as
an
Unresolved
Item (259,
260,
" 296/89-11-02)
pending further review of the single failure critdria used
by the licensee.
Resolution of IFIs
259,
260, 296/88-04-04
and 259,
260,
296/88-05-06 will be included in the resolution of this single
URI which
must
be resolved prior to restart of Unit 2.
No violations
or deviations
were identified in the
Design Deficiencies
area.
6.
Fire Prevention/Protection
- (42051)
An
NRC inspector toured the Units 1, 2,
and 3, reactor buildings, control
bay,
and turbine building to observe
the fire prevention
and protection
activities.
The
inspector
verified the
following conditions
to
be
in
effect:
wood scaffolding was marked
as being treated with flame retardant
there
was
no
unnecessary
accumulation
of combustible
forms,
form
lumber, shoring,
or scaffolding
fire extinguishers
and fire hoses
were
located at designated
places
at each elevation
access
to suppression
devices
was not restricted
by outage materials
or equipment
suppression
devices
indicated current inspection.
0
The
NRC inspector identified one concern in that there
was
a large
amount
of material
contained
in yellow plastic
bags
stored
within several
contamination
areas
located in the Unit 3 Reactor Building.
Since
some of
the yellow plastic
bags
appeared
to possibly contain combustible material,
the
NRC inspector identified this concern
to licensee
management.
After
evaluating
the condition, the licensee
stated that all of the material in
question
was
stored
in approved
locations
and that all
bags
contained
mi rror type insulations or other noncombustible material.
~ 1
e
No violations
or deviations
were
identified in the
Fire Prevention/
Protection
area.
Cable Deterioration
(62703)
During the performance
of a functional test of the Unit 2
IRM A channel
on
March
14,
1989,
a short circuit occurred
resulting
in the
power . supply
fuse blowing for that drawer.
The licensee
investigated
the cause of the
short
circuit
and
determined
that
various
cables
-in
the
Nuclear
Instrumentation
System were deteriorated
in that the rubber insulation
had
become brittle and
cracked with portions of the conductor
exposed.
This
problem is documented
on
CAQRs BFP890290,
BFP890291,
and
BFP890292.
V
The licensee
reported this problem to the resident
inspectors
on March
17.,
1989.
Based
on preliminary information, the
problem
was believed to
be
limited to General'lectric
supplied
GENIE
SJO
SI - 53115
power
cables
with black
Nitrile-PVC jacket.
The
conductor
insulation
is
styrene
butadiene
(Buna-S)
rubber insulation which was
known to have
been
used in
the
source,
intermediate,
and average
power range instrumentation
systems
at Browns Ferry.
The failure of the insulation material
appears
to
be embrittlement
and
cracking of the individual conductor's
rubber insulation after prolonged
exposed to air in the area
where the outer jacket was stripped
away during
termination
of
the
cables.
The
ozone
concentration
in
the
normal
atmosphere
causes
the material
to deteriorate.
Neither the cable
outer
jacket or conductor insulation
covered
by the jacket is expected
to
be
affected.
The licensee
is in the
process
of replacing
the
NI cables with properly
qualified cable.
The Division I NI cables
have
been
replaced
with the
Division II work remaining
to
be
completed.
Licensee
management
has
stated
that although
has notified the licensee that based
on
a sample
review of local'anels
there is probably
minimal
use
of thi s
type of
cable,
TVA has
requested
that
GE perform
a complete
review of local panels
for application.
Since
there
was
a possibility that the
same
type of cable
may have
been
used
on
other
Nuclear
Steam
Supply
System
(NSSS)
components
was
requested
to
manually
search
their
records
and
determine.
any
other
applications
for this type cable.
Based
on preliminary information from
17 other
BWRs built between
the late
1960s
and
1971 also
have this type cable
and
no prior problems with this type cable
have
been
identified.
GE replied via
GE Electrical
Design
Engineering
Memos dated
March 24,
and
March 27,
1989, that their review of control
room drawings
for Browns Ferry Unit 2 was
complete
and that this material
was
used
as
power
cable
for other
systems
in addition
to NIs.
Process
control
instrumentation
(GE-MAC), Area
Radiation
Monitors
(ARMs),
and
various
control
room recorders
were identified as also
being affected.
GE also
stated
that
a
RICSIL communication
(type of
immediate
action
SIL)
was
12
being issued to
BWR owners to provide formal notification and
recommenda-
tions.
made
a preliminary assessment
of available information associated
with
the problem and determined that it was not an immediate threat to safety.
This
assessment
is partial ly
due
to
the= fact that
the
associated
components
would fail due to loss of power if a electrical
short occurred,
resulting in any required
RPS or
ESF actuation
occurr'ing, i.e.
component
failure would result in fai lure in a nonconservative
manner.
GE has obtained
a .sample of the cable for further analysis to identify any
additional
reasons
for the deterioration
and will'be providing information
to
INPO on the issue.
The
NRC inspectors will follow the licensee's
progress
in this area during
future inspections.
Specifically the
NRC inspectors
are
concerned
about
the
proper identification
and
replacement
of defective
cables
in all
applications 'of this type cable in control
room and local panels
through-
out the plant.
Additionally the
NRC inspector will need to review any
licensee
and/or vendor generic evaluation that is performed.
This item is
identified as Inspector
Followup Item 259,
260, 296/89-11-03;
Deteriorated
GE Cables.
This item must
be resolved prior to restart of each respective
Unit.
No violations-=or deviations
were identified in the
Cable Deterioration
area.
8.
Reportable
Occurrences
(90712,
92700)
, The following licensee
events
reports
(LERs) were reviewed to determine:
adequacy
of event description,
verification of compliance with technical
specifications
and
regulatory
requirements,
corrective
action
taken,
existence
of potential
generic
problems,
reporting requirements
satisfied,
and the relative
safety significance .of each
event.
Additional in-plant
reviews
and 'discussions
with plant
personnel,
as
appropriate,
were
conducted.
0
(OPEN)
LER
296/89-03:
Unplanned
Engineered
Safety
Features
Actuations
Caused
By Voltage Transient
on Electrical
Distribution
'System.
On March 7,
1989,
Unit 3 received
an unplanned
ESF actuation
due to
voltage fluctuations in the alternate
power supply to the
RPS circuit
protectors
3Cl and
3C2, which caused
a momentary loss of power to
Bus 3B.
The normal
3B
RPS bus is supplied
by the
RPS motor generator
set
number
3B
and
the alternate
supply is
from
a unit preferred
!
0
e
13
regulatory transformer.
The
NRC inspector
reviewed the
LER as it may
affect Unit 2
power supplies
which are
the
same electrically
as
Unit 3.
The following drawings were reviewed:
Powerhouse
Unit 2,
Wiring
Diagrams,
Power
System
. Schematic
Diagram SH-4.
2-45E641-2,
Powerhouse
Unit 2,
Wiring Diagram
Instrumentation
and
Control
Power System,
Schematic
Diagram.
The
NRC inspector
noted that the alternate
power for the Unit 2
A
and
B is
a direct feed from the secondary
of a step
down transformer
480 to 120/240
Y, Unit Preferred
Regulatory Transformer
TVP-2, and is
consequently
susceptible
to voltage fluctuations
induced
by the
480
volt primary side
shared
loads
and the
240/120 volt secondary
side
shared
loads.
The
normal
supply to the
Bus
A and
Bus
B is
provided
by
a
480 to
120 volt motor-generator
set
equipped with a
flywheel and does
not have
a shared
load system
on the output of the
generator.
This
system
is
not readily susceptible
to voltage
and
load'fluctuations
on the
480 volt shared
power feed to the motor due
to
the
flywheel
and
the
electrical
isolation
provided
by
a
motor-generator
system.
The
NRC
inspector
also
noted
that
by
transferring
the Unit 3
Bus
3A to the alternate
source
in order
to perform
a
PM on March 1,
1989,
and by not performing the
PM in
a
timely manner," i.e.
when the event occurred approximately
seven
days
after the transfer,
the
PM still had
not
been
performed, this left
that
Bus
much
more susceptible
to electrical fluctuations.
The
licensee
stated
in the Unit 3
LER that administrative
steps
would be
taken
to
minimize
the
amount
of time all three
unit
power
supplies
would be
on the respective
alternate
power
feeds.
Also,
design
assumptions
for the circuit protectors
would
be .reviewed to
determine if they could
be
changed
to
make
the circuit protectors
less
sensitive.
This item will remain
open
pending further review
and corrective
action
must
be
in
place
prior to
Unit
2
power
operation.
(OPEN)
LER
260/89-08:
Electrical
Fault
on
Transformer
Causes
Engineered
Safety Features
Actuation.
On March
19,
1989,
an
ESF actuation
occurred
due to
an electrical
fault
on
the
Unit Station
Service
Transformer
(USST)
2B.
The
transfor'mer which i s located in the switchyard', failed resulting, in a
loss of power to th;; Shutdown
Bus 2.
This in turn, resulted
in
a loss
of power to the Shu:down
Boards
C and
D, which sensed
a
low voltage
condition
and
automatically
started
C
and
D.
During
the
restoration
of
the
electrical
system,
additional
actuations
occurred.,
The
NRC inspector
noted,
during the review of the
LER,
that plant
operations
personnel
initially believed
that this
was
caused
by
plant
electrical
maintenance
personnel
performing
maintenance
on
an undervoltage
relay.
This belief resulted
in the
operators
taking
inappropriate
action
while restoring
the
system.
14
The
licensee
determined
after the
event that the Shift Operations
Supervisor
(SOS)
had information that would have helped the operators
to find the problem faster but did not communicate this information
to Control
Room
personnel
until after
the event.
This item will
remain
open until all corrective
actions
are
complete
and
must
be
closed
prior
to
Unit
2
restart.
Corrective
action
includes
modification activities
scheduled
to
be
complete
in June,
1989
and
high-potential testing to prove the adequacy
of insulation.
No violations or deviations
were identified in the Reportable
Occurrences
area.
Site Management
and Organization
(36301,
36800,
40700)
The
NRC inspectors
attended
meetings
of senior managers
from Operations,
Haintenance,
Technical
Support,
and onsite
DNE in the
"War Room."
The
topics
of discussion
involved the
planning
and
.scheduling
of
system
outages,
the day to day workings of the
"War Room",
and frank discussions
of issues
and their priority as well
as
scheduling
impact.
Free
flowing
exchange~ of ideas,
information,
and questions
took place with each
group
presenting
planning
and
scheduling
issues.
Various
"War
Room"
committee
meetings
were held
on
a daily basis following the general
meeting
and the
NRC inspectors
attended
them periodically.
During this reporting
period,
the major topic of the meetings
was the
status
of the division outages.
The
NRC inspectors
noted that
numerous
problems occurred in the procurement
area during the
Phase I, Division I
outage.
The
problems
associated
with obtaining materials
caused
the
postponement.
of
several
of
the
scheduled
work activities.
Licensee
management
showed
an increased
interest
and involvement in this area
each
day
and
fewer
materials
problems
were
noted
during
the
Phase
I,
Division II outage.
During the event associated
with the failure of USST 2B, as discussed
in
Paragraph
8, licensee
management
failed to communicate
with control
room
personnel
about
information
related
to the electrical
failure.
This
resulted
in
a delay in
an operational
evaluation
of potential
hazards.
The
NRC
inspectors
are
concerned
that this failure might not
be
an
isolated
case
and could have resulted
in a more significant event.
A concern
was
noted
by the inspector with the security force rotating
shift
assignments.
The
NRC
inspector
noted
that
the
forward shift
rotation in the direction
from the night shift to the evening shift and
then
to the
day shift, is contrary to
human factors engineering.
The
recognized
and preferred shift rotation is
from the
day shift to the
evening shift
and then to the night shift. It has
been
documented
by
experience
that
by requiring
a forward rotation,
unnecessary
stress
and
fatigue is placed
on shift workers.
Another concern
deals with middle
management
meetings,
specifically that
two types
of significant daily
meetings
were
being
conducted
on site.
One meeting,
the daily outage
meeting,
was
being
held at 6:30
a.m.
and
2:30
p.m.
and dealt with the
15
continuing
outage
work.
The
other
meeting,
the daily
shi ft turnover
meetings,
were conducted at 7:00 a.m.,
3:00 p.m.
and
11:00
p.m.
and were
attended
by the
oncoming operations
shift personnel,
The 'NRC inspector
noted that first line supervisors
and
managers
who attended
the earlier
meeting
and received
the information about
upcoming work activity could
then attend
the
operators
turnover
meetings
to
ensure
a
good line of
communication
to the
oncoming shift operators.
However,
recently
the
operators
meeting
was
changed
to 6:30 a.m.,
?:30
p.m.,
and
10:30
p.m.
Thus,
both meetings
are being conducted at the
same time.
During this
inspection
period,
the
licensee
has
continued
to replace
middle and senior
management.
While these
changes
are
considered
by the
NRC as positive efforts to address
plant and programmatic
weaknesses,
they
initially have
an
impact
on the plants ability to. maintain
an
arduous
schedule
leading 'to restart.
All of these
proven,
competent individuals
must have
some time in order to coalesce
into a team that will be able to
resolve
past
licensee
weaknesses
and provide leadership
into, the restart
and operations
mode.
A new position
was created
called
Engineering
and
Modifications Restart
Manager,
reporting directly to the Site Director
with both the
DNE and Modifications groups reporting to him.
The Project
Engineer
has
been
replaced
and
various
middle
managers
have
been
realigned.
The only key managment
slot still vacant is the
Maintenance
Manager,
whose duties
are
being carried out by the Plant Manager unti 1
a
permanent
replacement
is selected.
Exit Interview (30703)
The inspection
scope
and findings were
summarized
on April 14,
1989 with
those
persons
indicated
in paragraph
1 above.
The inspectors
described
the areas
inspected
and discussed
in detail the inspection findings listed
below.
The licensee
did not identify as proprietary
any of the material
provided
to
or
reviewed
by
the
inspectors
during
this
inspection.
Dissenting
comments
were not received
from the licensee.
Item
259,
260, 296/89-11-01:
Descri tion
Violation, Failure to Satisfy
T.S. 3.2.A (paragraph
2)
296,89-11-05
259,
260, 296/89-11"02:
'4
~
<4aw~
L
259,
260, 296/89-11-03:
Violation, Failure to Satisfy
TS
~
4. 6. B. 1. C. (paragraph
2)
Unresolved
Item, Potential
Failure to
Satisfy Single Failure Criteria
(paragraph
5)
Inspector
Followup Item, Deteriorated
GE Cables
(paragraph
7)
P
~
-16
Item
(cont'd)
260/89-11-04:
10.
Descri tion
Non-cited Violation, Failure
to Follow Special
Operating Instruction
(paragraph
2)
CAQR
IFI
LER
LIV
LRED'OV
NI
NRC
RCW
SDSP
SOS
TS
USST
Area Radiation Monitor
Boiling Water Reactor
Condition Adverse to Quality Report
Diesel
Generator'ivision of Nuclear
Engineering
Engineering
Change
Notice
Emergency
Equipment Cooling Water
Engineered
Safety
Feature
Inspector
Followup Item
Institute of Nuclear Plant Operations
Intermediate
Range Monitor
Immediate Temporary
Change
Licensee
Event Report
Licensee Identified Violation
Licensee
Reportable
Event Determination.
Motor 0'perated
Valve
Nucelar Instrumentation
Nuclear Regulatory
Commission
Nuclear
Steam
Supply System
Preventive
Maintenance'ost
Maintenance/Modification
Test
Raw Cooling Water
Residual
Heat
Removal
Residual
Heat
Removal
Reactor Protection
System
Site Director Standard
Practice
Standby
Gas Treatment
System
Surveillance
Instruction
Service Information Letter
Shift Operations
Supervisor
Senior Reactor Operator
Technical Specifications
Valley Authority
Violation
Unresolved
Item
Unit Station Service Transformer