ML20029E510
| ML20029E510 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 05/12/1994 |
| From: | Beach A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | Cottle W HOUSTON LIGHTING & POWER CO. |
| References | |
| NUDOCS 9405180433 | |
| Download: ML20029E510 (32) | |
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p* MGg UNITED STATES gf k
NUCLEAR REGULATORY COMMISSION 4]i REGION IV YI 8
611 RY AN PLAZA DRIVE, SUITE 400
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AR LINGTON, T E X AS 76011 8064 g
MAY I 21994 Dockets:
50-498 50-499 Licenses: NPf-76 NPF-80 Houston Lighting & Power Company ATTN: William T. Cottle, Group Vice President, Nuclear P.O. Box 289 Wadsworth, Texas 77483
SUBJECT:
MAY 4, 1994, MANAGEMENT MEETING This refers to the meeting conducted at the NRC's request at the South Texas Project site on May 4, 1994. The meeting dealt with staadby diesel generator (SDG) issues, Unit 1 performance, ano Unit 2 startup preparations.
The NRC staff requested this meeting to provide updated information as a part of a series of meetings which have been held during the extended outage and restart process for the South Texas Project units. An additional meeting will be conducted prior to the restart of Unit 2.
This meeting was open for public observation and was attended by those on the attached attendance list.
The SDG discussion included the failure analyses and corrective actions taken and planned for the voltage regulation problems on SDG 11, the piston damage on SDG 22, the inadvertent autostarts on SDG 21, and the fuel injection pump stud failures on SDG 22. We understand that you plan to perform periodic inspections of SDG 22 to monitor for indications of unusual wear or damage.
We understand that you plan to perform a modification on the other five SDGs similar to the modification performed on SDG 22 to improve piston / cylinder lubrication and that you will inform the NRC of your plans and schedule for these modifications.
The hollow fuel injection pump studs have been replaced with solid studs on the three Unit 2 SDGs.
We understand that you plan to perform a similar modification on the Unit 1 SDGs and that you will inform the NRC of your plans and schedule for these modifications..The system-certification process for Unit 2 SDGs was in progress and you committed to provide the completed package for NRC review.
Should your understanding-of these commitments differ from ours, please contact me promptly.
The Unit 1 performance discussion included accomplishments and self-assessment results, including areas which warrant increased management attention.
The Unit 2 startup preparation discussions included accomplishments, challenges, and schedules.
You noted that Unit 2 startup preparations-are continuing'with a deliberate, methodical approach, incorporating lessons learned during the recent Unit I restart experience.
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Houston Lighting & Power Company l 2 1994 bcc to DMB (IE45) bcc distrib by RIV:
L. J. Callan Resident inspector Branch Chief (DRP/A)
Leah Tremper, OC/LFDCB, MS: MNBB 4503 MIS System DRSS-FIPB RIV File Project Engineer (DRP/A)
R. Bachmann, OGC, MS: 15-B-18 Branch Chief (DRP/TSS) l O
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Houston Lighting & Power Company '
i In accordance with Section 2.790 of the NRC's " Rules of Practice," Part 2, Title 10, Code of Federal Regulations, a ccpy of this letter and its attachments will be placed in the NRC's Public Document Room.
Sincerely, bff) '
A. BVfl Beach, Dire tor Division of Reactor Projects Attachments:
1.
Attendance List 2.
Licensee Presentation cc w/ attachments:
Houston Lighting & Power Company
^TTN:
James J. Sheppard, General Manager Nuclear Licensing P.O. Box 289 Wadsworth, Texas 77483
-l City of Austin Electric Utility Department ATTN:
J. C. Lanier/M. B. Lee 721 Barton Springs Road Austin, Texas 78704 City Public Service Board ATTN:
K. J. Fiedler/M. T. Hardt P.O. Box 1771 San Antonio, Texas 78296 Newman & Holtzinger, P. C.
ATTN:
Jack R. Newman, Esq.
1615 L Street, NW Washington, D.C.
20036 Central Power and Light Company ATTN:
G. E.-Vaughn/T. M. Puckett P.O. Box 2121 Corpus Christi, Texas 78403 1
INP0 Records Center 700 Galleria Parkway
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Atlanta, Georgia 30339-5957 i
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Houston Lighting & Power Company Mr. Joseph M. Hendrie
' 50 Bellport Lane Bellport, New York 11713 Bureau of Radiation Control State of Texas
- 1100 West 49th Street Austin, Texas 78756 Judge, Matagorda County Matagorda County Courthouse 1700 Seventh Street Bay City, Texas 77414 Licensing Representative Houston Lighting & Power Company Suite 610 Three Metro Center Bethesda, Maryland 20814 Houston Lighting & Power Company ATTN:
Rufus S. Scott, Associate General Counsel P.O. Box 61867 Houston, Texas 77208 Shaw, Pittman, Potts & Trowbridge ATTN: Joseph R. Egan,'Esq.
2300 N Street, N.W.
Washington, D.C.
20037 i
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a Houston Lighting & Power Conipany l 2 1994 bcc to DMB (IE45) bcc distrib. by RIV:
L. J. Callan Resident Inspector Branch Chief (DRP/A)
Leah Tremper, OC/LFDCB, MS: MNBB 4503 MIS System DRSS-FIPB RIV File Project Engineer (DRP/A)
R. Bachmann, OGC, MS: 15-B-18 Branch Chief (DRP/TSS) n yt!
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ATTACHMENT 1
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ATTENDANCE LIST PURPOSE OF MEETING: MANAGEMENT MEETING - UNIT 2 STATUS AND STANDBY DIESEL GENERATOR ISSUES LOCATION: SOUTH TEXAS PROJECT SITE DATE:
MAY 4,.1994 TIME: 10 a. m.
NAME (PLEASE PRINT)
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MAY 4,.1994 TIME: 10 a. m.
NAME (PLEASE PRINT)
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MAY 4, 1994 TIME:
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ATTENDANCE LIST PURPOSE OF MEETING: MANAGEMENT MEETING - UNIT 2 STATUS AND STANDBY DIESEL GENERATOR ISSUES LOCATION: SOUTH TEXAS PROJECT SITE DATE:
MAY 4, 1994 TIME:
10 a. m.
NAME (PLEASE PRINT)
ORGANIZATION TITLE l
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ATTACHMEitT 2' 1
1 SOUTH TEXAS PROJECT HL&P and NRC Management Meeting May 4,1994 VISION: STP -- A WORLD-CLASS POWER PRODUCER m
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g AGENDA I.
OPENING REMARKS J. F. GROTH l
II.
STANDBY DIESEL GENERATORS T. J. JORDAN l
S. E. THOMAS III.
UNIT 1 PERFORMANCE L. W. MYERS
- IV. UNIT 2 STARTUP PREPARATION G. L. PARKEY V.
CLOSING REMARKS J. F. GROTH l
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1 STANDBY DIESEL GENERATOR ISSUES SDG 11 VOLTAGE REGULATION i
SDG 22 PISTON SKIRT SDG 21 FIBER OPTIC CIRCUIT SDG 22 FUEL INJECTION PUMP
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t SDG 11 VOLTAGE REGULATION - REVIEW OF ISSUE SDG 11 DID 'NOT ACHIEVE RATED VOLTAGE DURING SURVEILLANCE TESTS ON FEBRUARY 3 AND MARCH 1,1994 CAUSE - FAULTY RESET COIL SPRING AND BAD CONTACTS IN THE K1 RELAY CONTACTOR a
REPLACED FIELD FLASH CIRCUIT COMPONENTS IN SDG 11 INCLUDING THE FAULTY K1 RELAY'CONTACTOR SDG 11 PERFORMING SATISFACTORILY f
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SDG 22 PISTON SKIRT - REVIEW OF ISSUE PISTON SKIRT 4R WAS FOUND BROKEN DURING A SCHEDULED PERIODIC INSPECTION PROBABLE CAUSE - FOREIGN MATERIAL CAUSED LOCALIZED HEATING WHICH CRACKED PISTON.
REPLACED 4R PISTON AND CYLINDER LINER MODIFIED SDG 22 TO IMPROVE PISTON / CYLINDER LUBRICATION COMPLETED SPECIAL 168 HOUR ENGINE RUN TEST FOR SDG 22 INSPECTED LOWER END OF CYLINDERS AFTER SPECIAL TESTING -
NO ADVERSE INDICATIONS.
RETURNED SDG 22 TO SERVICE PERIODIC BOROSCOPIC INSPECTIONS OF THE LOWER END OF
. CYLINDERS WILL CONTINUE Page 6 r
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SDG 21 FIBER OPTIC CIRCUIT - REVIEW OF ISSUE SDG 21 RECENTLY STARTED ON THREE SEPARATE OCCASIONS WITHOUT RECEIVING A VALID START SIGNAL CAUSE: IST/2ND START - FAULTY FIBER OPTICS.
3RD START - UNDER INVESTIGATION REPLACED FAUL,TY FIBER OPTICS IN SDG 21. INSTALLED WARNING SIGNS ON THE SDG CONTROL PANELS TO LIMIT ACCESS AND PROVIDE WARNING ON THE USE OF FLASHLIGHTS AND RADIOS WITHIN THE PANELS.
WILL ENHANCE PREVENTIVE MAINTENANCE TO INSPECT / TEST /
REPLACE FIBER OPTIC BOARDS PERIODICALLY EVALUATING PROPOSED ENGINEERING SOLUTION BY COOPER ENTRONICS TO USE ISOLATION RELAYS IN PLACE OF FIBER OPTICS t-RECENT TEST HISTORY GOOD Page 7
SDG 22 FUEL INJECTION PUMP i
FUEL. INJECTION PUMP STUDS FOR CYLINDER 6L FAILED DURING A POST MAINTENANCE TEST RUN. THE PUMP DETACHED FROM THE PEDESTAL.
SIMILAR PREVIOUS FAILURES ON SDG 22 i
EXTENSIVE INVESTIGATION WITH INDUSTRY EXPERTS PERFORMED TO DETERMINE ROOT CAUSE FAILURE HISTORY INSTALLATION METHODS 1
DESIGN OF STUD, NUT, PUMP BASE, PEDESTAL, AND CAM l
METALLURGY i
VIBRATION l
FUEL SYSTEM Page 8
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SDG 22 FUEL INJECTION PUMP (CONT'D)
NO DEFINITIVE SINGLE ROOT CAUSE LIKELY CA.USES LOSS OF PRELOAD l
4 MATERIAL / MANUFACTURING DEFECT l
OVERSTRESS 1
i CONDITIONS-UNIQUE TO SDG 22 CONSERVATIVE CORRECTIVE ACTIONS FOR SDG 22 WERE TAKEN WHICH ENVELOPE THE LIKELY INITIATING MECHANISMS
-REPLACED HOLLOW STUDS WITH SOLID STUDS INCREASED PRELOAD TORQUE 1
Page 9
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4 SDG 22 FUEL INJECTION PUMP (CONT'D)
CORRECTIVE ACTIONS (CONT'D)
REPLACED NYLOK NUT WITH HEAVY HEX NUT AND BELLEVILLE WASHER REVISED INSTALLATION METHODS VERIFIED PRELOAD TORQUE AFTER 24 HOURS OF ENGINE RUN ENHANCEMENT TO OTHER SDGs TO IMPROVE DESIGN MARGINS l
MODIFICATION IMPLEMENTED ON SDG 21 AND 23 DEVELOPING PLAN-FOR UNIT l'SDGs
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STANDBY DIESEL GENERATOR PERFORMANCE (SINCE 3/1/94)
SDG ATTEMPTS /STA~RTS HOURS RUN TIME 11 12/12 39 12 3/3 10 13 3/3 7
21 17/17 40*
22 18/18 175*
23 7/7 20*
- SDG 21, 22 & 23 SUCCESSFULLY COMPLETED LOSS OF OFFSITE POWER, LOSS OF OFFSITE POWER-SAFETY INJECTION, ENGINEERED SAFETY FEATURES ACTUATION SURVEILLANCE TESTING Page11
I STATUS AND CURRENT SCHEDULE FOR SDG ENHANCEMENT PLAN CONTROL CIRCUITRY IMPROVEMENTS RECOMMENDED BY MPR ASSOCIATES INDEPENDENT ASSESSMENT (7/94)
PROCEDURE REVISIONS FOR IMPLEMENTATION OF MAINTENANCE RULE (12/94)
TECHNICAL SPECIFICATION REVISION TO CHANGE SDG STARTING AND LOADING REQUIREMENTS (6/94)
STANDARDIZATION OF ENGINE BA. LANCING TECHNIQUES (6/94)
STANDARDIZATION OF PROCEDURES FOR REPEATED OPERATING AND M'AINTENANCE TASKS (12/94)
ENHANCE SURVEILLANCE PROCEDURES (12/94)
ENHANCE SPARE PARTS PROGRAM (6/94)
STANDARDIZATION OF TROUBLESHOOTING PROCEDURES FOR RAPID RESPONSE (12/94)
Page 12
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STATUS AND SCHEDULE FOR SDG ENHANCEMENT PLAN (CONT'D)-
ENHANCE SDG TRENDING PROGRAM (7/94)
SYSTEM ENGINEER TRAINING (ONGOING) 4 i
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SUMMARY
OF STANDBY DIESEL GENERATORS ISSUES THOROUGHLY INVESTIGATED, CAUSES IDENTIFIED, AND CORRECTIVE ACTIONS IMPLEMENTED CORRECTIVE ACTIONS HAVE BEEN EFFECTIVE TEST RUNS HAVE BEEN SATISFACTORILY COMPLETED RECENT PERFORMANCE HISTORY FAVORABLE CONTINUING TO IMPLEMENT OUR OVERALL SDG IMPROVEMENT PLAN SDGs CAPABLE OF PERFORMING SAFETY FUNCTION AND SUPPORT THE RETURN OF UNIT 2 TO SERVICE F
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UNIT 1 ACCOMPLISHMENTS ONLINE 42 DAYS IMPROVED SCHEDULE ADHERENCE ACCREDITATION RENEWAL FOR OPERATIONS AND ENGINEERING SUPPORT TRAINING PROGRAMS COMPLETED POWER ASCENSION PROGRAM COMPLETED 100% POWER PLATEAU SELF-ASSESSMENT COMPLETED REDUCED POWER OUTAGE FOR MAINTENANCE ACTIVITIES REPAIRED CONDENSATE SYSTEM SOCKET WELD REPAIRED #12 FEEDWATER BOOSTER PUMP SEAL CLEANED FEEDWATER PUMP TURBINE OIL COOLERS REPLACED MAIN TRANSFORMER COOLING FAN / PUMP BREAKER REPAIRED SEVERAL MINOR SECONDARY STEAM LEAKS Page 16
k UNIT 1 OBJECTIVES 4
CONTINUED ERROR-FREE POWER OPERATION CONTINUED TRANSITION TO AN OPERATING PLANT ENVIRONMENT ENHANCEMENTS IN WORK CONTROL PROCESS
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4 UNIT 1
SUMMARY
UNIT 1 IS OPERATING SUCCESSFULLY P.ROBLEMS ARE BEING IDENTIFIED AND RESOLVED PERFORMANCE CONTINUES TO IMPROVE l
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L UNIT 2 ACCOMPLISHMENTS-SYSTEM CERTIFICATION. PROGRAM STARTUP AND POWER ASCENSION PLAN J
SERVICE REQUEST BACKLOG REDUCTION MOTOR OPERATED VALVE TEST PROGRAM t
REACTOR COOLANT SYSTEM FILLED AND VENTED WITH BUBBLE IN t
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SECONDARY PLANT IN CONDENSATE LONG PATH CLEANUP l
Page 20
UNIT 2 SYSTEM CERTIFICATION WALKDOWNS & APPROVALS status as of 5/02/94 NO OF SYSTEMS 70
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UNIT 2 PREVENTIVE & CORRECTIVE MAINTENANCE SERVICE REQUESTS 3,000 2772 2,750 2,500
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UNIT 2 CHALLENGES COMPLETION OF SURVEILLANCE TESTING 1
STEAM GENERATOR FEED PUMP TESTING TO SUPPORT POWER
' ASCENSION GENERAL PLANT CLEANUP BALANCING RESOURCES TO SUPPORT CONTINUING IMPROVEMENTS IN UNIT 1 WITH UNIT 2 STARTUP t
Page 23
UNIT 2 POWER ASCENSION SCHEDULE 10038 Full Power Operation Q i
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1 UNIT 2
SUMMARY
4 PREPARING FOR MODE-4. ENTRY AND POWER ASCENSION CONTINUING DELIBERATE, METHODICAL APPROACH CAPITALIZING ON EXPERIENCE WITH UNIT 1 i
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