ML20080G932
| ML20080G932 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde |
| Issue date: | 10/04/1983 |
| From: | ZYTOR, INC. |
| To: | |
| Shared Package | |
| ML20080G796 | List: |
| References | |
| CON-NRC-IE-82-83-46C, FOIA-83-598 HSB:PAR0003, HSB:PAR3, NUDOCS 8402140048 | |
| Download: ML20080G932 (158) | |
Text
{{#Wiki_filter:- - - - ZYTOR, INC. f v3 r" ID. t', FINAL REPORT PALO VERDE STATION HPSI SYSTEM ELECTRICAL AND INSTRUMENTATION CONSTRUCTION AUDIT INSPECTION Prepared for: PARAMETER, INC. 13380 WATERTOWN PLANK ROAD ELM GROVE, WI 53122 Contract NRC-IE-82/83-46C Prepared by: ZYTOR, INC. SUITE 101 2542 SOUTH EASCOM AVENUE CAMPBELL, CA 95008 (408) 559-4061 l Job Number PAR-0003 l .l Revision: 0 l Date: October 04, 1983 t r.y,~ ?- , "e Reviewed: Approved: 0402140040 831220 HSB: PAR 0003.Pi1 PDR FOIA DERNABE83-598 PDR 0/ 70
~ ~ i ZYTOR, INC. R-Tablo of Contents (.. Page b Section Title 4 6.5-1 VI.5 CABINETS AND PANELS 6.5-1 6.5.1 Procurement Records Equipment and Recor'ds Inspected 6.5-2 6.5-3 6.5.2 S torage Records 6.5-3 6.5.3 Installation Records M 6.5-3 6.5.4 Maintenance Records 6.5.5 Internal Wiring, Controls, and Displays 6.5-3 6.5-3 6.5.6 Cabinet to Cabinet Wiring Tracing Storage, Install., Maint. Records 6.5-4 6.5-6 6.5.7 Cabinet and Panel Conclusions 6.7-1 VI.7 BATTERIES AND RACKS 6.7-1 6.7.1 Intercell and Terminal Detail Resistance 6.7.2 Maintenance Data and Acceptance Criteria 6.7-3 6.7.3 Battery Rack Spring Nut Alignment 6.7-3 Battery Test Data Discrepanc'ies 6.7-4 6.7.4 Battery Load Capacity Test Results 6.7-5 6.7.5 Battery, Charger, and Inverter Conclusions 6.7-6 6.7-7 Document References 6.7-8 Personnel Interviewed IM 2 RE N M . M:ila.. ,4 - s. Page 11 HSB: PAR 0003.Pi2 En
ba M ZYTOR, INC. VI.5 Cabinets and Panels ,__3 L-*l The NRC Construction Appraisal Team (CAT) performed an inspection of the HPSI system main control room panels; solid-state and relay panels; PPS cabinets; isolation cabinets; analog instrument cabinets, and the remote shutdown panel. Cabinets and panels for both HPSI train A and train B were inspected for mounting arrangements; internal wire routing p --$ for separation; cable markings; termination connections; podule e "~~~] mountings; operator controls and displays, and general workmanship ahd cleanliness. The specific cabinats and panels inspected are " highlighted" in the following list: { i 6-4 NSSS Analog Instrument Cabinets A, B, C, and D; 1-J-SBA-C02A 1-J-SBB-C02A 1-J-SBC-C02A 1-J-SBD-C02A 1-J-SBA-C02B 1-J-SBB-C02B Plant Protection System Cabinets A, B, C, and D; 1-J-SBA-C01 1-J-SBB-C01 1-J-SBC-C01 1-J-SBD-C01 M Main Control Room Panels; 1-J-RMA-B02 1-J-RMB-B02 1-J-RMC-B02 1-J-RMD-B02 I=~1 1-J-RMA-B05 1-J-RMB-B05 1-J-RMC-B05 1-J-RMD-B05 b-J 2-J-RMA-B02 2-J-RMB-B02 2-J-RMC-B02 2-J-RMD-B02 2-J-RMA-B05 2-J-RMB-B05 2-J-RMC-B05 2-J-RMD-B05 ESFAS Auxiliary Relay Cabinets A and B; 1-J-SAA-C01 1-J-SAB-C01 E BOP ESFAS Cabinets A and B; 1-J-SAA-C02A 1-J-SAB-C02A 1-J-SAA-C02B 1-J-SAB-C02B Isolation Cabinets A, B, C, and D; 1-J-SAA-C04 1-J-SAB-C04 1-J-SAC-C04 1-J-SAD-C04 Status Display Panel Inserts A and B; 1-J-ESA-C01 1-J-ESB-C01 M Remote Shutdown Panet Sections (HPSI Valve Controls) 1-J-ZJA-E01 1-J-ZJB-E01 1-J-ZJC-E01 1-J-ZJD-E01 [__J In addition to the physical inspection of egoipment and tracing of a portion of interconnecting cable, procurement records, equipment storage records, installation records, and maintenance records were also examined as shown on page 6.5-2. l ) 6.5.1 Cabinet and Panel Procurement Records 377 Technical requirements were reviewed for the main control room panels and thle relay panels contained in procurement specifications 13-J,M2200 to Comsip, Inc. and 13-EM-022 to Harlo Corp. respectively. These E records are acceptable, and are maintained in a controlled and current ~ status manner. Page 6.5-1 HSB: PAR 0003.P01 IM 9-
ZYTOR, INC. EQUIPMENT AND RECORDS INSPECTED INSPECTION OF EQUIPMENT (CAT)---------------------I MAINTENANCE RECORDS----------------------I I INSTALLATION RECORDS----------I I I l STORAGE RECORDS-----I I I I l I I I I 1-J-CHA-HV531 SUCTION VALVE l SIB-UV616,-626,-636,-646 ~ X X l SIA-UV617,-627,-637,-647 X J-SBA-C02A INSTRUM. RACK X X X t J-SBA-C02B X X J-SBB-C02A X X X l J-SBB-C02B X l J-SBC-C02A X X J-SBD-C02A " X X M J-SBA-C01 CABINET X X X J-SBB-C01 X X X , j J-SBC-C01 X X J-SBD-C01 X X i J-SAA-C02A " X X l J-SAA-C02B X X J-SAB-C02A X X J-SAB-C02B " X X X J-SAA-C01 X X X j J-SAB-C01 X X X J-RMA-B02 X X X M J-RMA-B05 X X X J-RMB-B02 X X X J-RMB-B05 X X X J-RMC-B02 X X X l J-RMC-B05 X X X I l J-RHD-B02 X X X j J-RMD-B05 X X X l J-SAA-C04 X X X J-SAB-C04 X X J-SAC-C04 X X X J-SAD-C04 X X X l J-ESA-C01 X X X J-ESB-C01 X X X E-PKA-F11 BATTERY X X X X E-PKB-F12 " X X X X l E-PKC-F13 " X X X X E-PKD-F14 " X X X X E-PNA-N11 INVERTER X X X E-PNB-N12 " X X X E-PNC-N13 X X X E-PND-N13 "- X X X E-PKA-H11 CH,ARGER X X X E-PKB-H12 "'- X X X ~ M ESPKCH13 " X X X E-PKD-H14 X X ~ X Page 6.5-2 HSB PAR 0003.P02 IllE o
ZYTOR, INC. I 6.5.2 Cabinet and Panel Storage Records Storage records for cabinets and panels prior to their installation were inspected to the extent that they were availsble. These records were found to be ancomplete as illustrated by the listing on page 6.5-4. (Finding 6.5.1) 4 6.5.3 Cabinet and Panel Installation Records l An installation specification for instrumentation and control equipment, 13-JM-702 revision 8 dated April 1, 1983, was reviewed M relative to cabinets and panels. Installation and installation modification records for these cabinets and panels during the 1980 through 1983 period were also inspected. These records are controlled, complete, and kept in a current status. 4 6.5.4 Cabinet and Panel Maintenance Records Cabinet and panel maintenance record problems were addressed by an l April 1981 NRC audit and an internal APS QA audit in August 1981. Post-installation maintenance procedures and records, involving cabinet protective covers, space heating, and humidity monitoring, were inspected I for the period from November 1981 up to where the equipment was turned over to Bechtel Startup. These records were controlled and complete. Once turnover has occurred, this type of monitoring is not continued as the panels are considered to be " energized." An internal separation barrier cover was missing from the 1-J-ZJB-E01 Remotc Shutdown Panel, and no status tag noting its removal was observed. (Finding 6.5.2) Periodic maintenance data records for the 1-J-SAA-C02A, BOP ESFAS Cabinet "A", do not contain an identification that the humidity indicator was either blue or pink for the period between November 21, 1979 and June 13, 1981. Subsequent data indicates that the humidity indicator was blue M (normal). These records precede the internal APS QA audit performed in August 1981. i 6.5.5 Cabinet and Panel Internal Wiring, Controls, and Displays Physical inspection of internal wire routing and separation, cable markings, termination connections, module mountings, and overall workmanship was performed at approximately 75% of the cabinets and panels housing HPSI components. Operator controls and displays for the HPSI system were examined at the B02.and B05 main. control room benchboards. M The interface between the HPSI system and the remote shutdown panel was l also examined. sre ~ 6.5.6 Cabinet to Cabinet cable Tracing Q y:.
- dFUsing the USNRC low-level signal tracer probe, one control circuit ll in'volving MOV 1-J-SIA-UV637 thermal overload bypass was. temporarily
^ Page 6.5-3 HSB: PAR 0003.P03
Cabinet and Panel Storage, Installation, and Maintenance Records i Name Number Received Insta1 led Maintenance NSSS Analog Inst. Rack 1-J-SBA-C02A 122179 100680 110981 NSSS Analog Inst. Rack 1-J-SBA-C02B 122179 100680 NSS'S Analog Inst. Rack 1-J-SBB-C02A 122179 100680 110981 Inst. Rack 1-J-SBB-C02B 122179 100680 M NSSS Analog NSSS Analog Inst. Rack 1-J-SBC-C02A 122179 020981 050980-110081 NSSS Analog Inst. Rack 1-J-SBD-C02A 122179 020981 050980 PPS Cabinet A 1-J-SBA-C01 051980 060780 070280 PPS Cabinet B 1-J-SBB-C01 051980 060780 070280 M, PPS Cabinet C 1-J-SBC-C01 061780 070280 PPS Cabinet D 1-J-SBD-C01 051980 061780 070280 DOP ESFAS Cabinet A 1-J-SAA-C02A 012480 042579-060882 BOP ESFAS Cabinet A 1-J-SAA-C02B 0208E0 110981-060982 BOP ESFAS Cabinet B 1-J-SAB-C02A 012480 042579-060882 BOP ESFAS Cabinet B 1-J-SAB-C02B 020880 110981-060782 i l B E ESFAS Aux. Relay A 1-J-SAA-C01 051580 061780 070280-020982 ESFAS Aux. Relay B 1-J-SAB-C01 061780 110981-020782 ESF Main CR Panel ABCD 1-J-RMN-B02 012279 082580 082780-110981 Main CR Benchboard 1-J-RMN-B05 041279 100980 110981 M Isolation Cabinet A 1-J-SAA-C04 012480 110981-060782 Isolation Cabinet B 1-J-SAB-C04 110981-050882 .B],; Isolation Cabinet C 1-J-SAC-C04 012480 110981-060782 Isolation Cabinet D 1-J-SAD-C04 012480 110981-060782 Status Display A 1-J-ESA-C01 012480 110981-080682 Status Display B 1-J-ESB-C01 012480 110981-080682 . y -,. fc:.. Page 6.5-4 HSB: PAR 0003.PO4 l _r
ZYTOR, INC. removed from service and traced for proper cable routing from MCC 1-E-PHA-M3322 at elevation 100' in the Auxiliary Building through conduit, cable trays, and cable risers to the designated K308-3 relay located in panel 1-J-SAA-CC103 at elevation 140' of the Control Building. M Measurement.s ueing the signal probe were directly compared with the cable pull card for this selected circuit. A number of measurements of other separation division cable trays and non-safety-related table trays were M also made to confirm the absence of the injected signal in these lo'ations. Correct cable routing up to the point of entry into the c cabinet was observed for this exampi.e. An error was noted in FSAR Table 6.2.4-2 regarding the "EA" and "EB" power assignments for HPSI isolation valves SIA-UV617, SIA-UV627, SIA-UV637, SIA-UV647, and SIB-UV616, SIB-UV626, SIB-UV636, and SIB-UV646. M Physical inspection of the installed equipment relative to electrical schematic and one-line drawings confirmed the proper motor control center assignment for each valve and that correct markings were provided on installed electrical conduit. APS initiated an FSAR Change Notice to M correct this minor documentation error. (Observation) The RWT suction valve to the HPSI system, 1-J-CHA-HV531, was physically inspected for its PHA-M3515 MCC power source and electrical conduit designations relative to plant drawings. BH At cabinet 1-J-SBA-C02B, confusion in the labelling of one cable gutter conduit relative to the cable pull card was observed. The routing via 1EZJ3AAKSBPG would cause the cable to enter cabinet 1-J-SBA-C02A rather than its designated destination of cabinet 1-J-SBA-C02B. Markings on the BE cable gutters match the installation drawings; however, time and access limitations prevented resolution of the inter-cabinet cable routing. (Unresolved item 6.5.1) BII During the inspection, it was observed that PVNGS drawings readily depict the assignment of 120 volt Vital AC power sources to particular NSSS analog instrument cabinets, but do not explicitly identify the internal 15 to 40 volt DC instrument loop power source required for individual HPSI transmitters on either Bechtel or Combustion Engineering drawings. This information was subsequently determined from a Foxboro technical manual and its related maintenance instruction. (Observation) The following cable tray hangers were inspected and found to conform with the installation detail drawings: j Cable Tray Hanger Number Detail Drawing Number and Revision 1EZJ2ABTYCJ 1EZJ2AH74 39-1 13EZJC-006 R20;-042 R12;-027 R10 1EZJ2ABTYCK 1EZJ2AH76 39-1 13EZJC-042 EllfI" 1EZJ2ABTYAM~ 1EZJ2AH75 12-3 13EZJC-022 R137 l 1EZJ2ABTYCK 1EZJ2AH80 39-3 13EZJC-027 R10 1EZJ2ABTYAWe 1EZJ2AH79 12-2 13EZJC-022 R13 142-J2ABTYAP ~ 1EZJ2AH60 12-1 13EZJC-022 R13 M '1EZJ2ABTYBH 1EZJ2AH61 12-1 13EZJC-022 R13 ' 1EZJ2ANTYVD 1EZJ2AH62 12-1 13EZJC-022 R13 1EZJ2ABTYAM 1EZJ2AH77 12-2 13EZJC-022 R13 Page 6.5-5 HSB: PAR 0003.P05 l
l'"1 ZYTOR, INC. During the inspection, the following cables were physically traced using cable pull cards and cabling diagrams: Cable Number From To Cable Feet 1EBC64BC1XD 1-J-ZJB-E02 1-J-SBB-C02A 284 Remote Shutdown Panel NSSS Analog Cabin.et 318 1ESB'01AC1RM 1-E-PNA-D25 1-J.SBA.CO2B Power Dist. Panel NSSS Analog Cabinet l 1ESB01AC1RS 1-E-PNA-D25 1-J-RMA-B02B 442 Power Dist. Panel ESF Control Room Panel f 1EPN02AC1RB 1-J-SAA-C04 1-E.PNA-N11 298 Isolation Panel Vital AC Inverter E!I l 6.5.7 Cabinet and Panel Conclusions I The overall impression for the construction phase for the cabinets and panels is high quality and excellent conformance with industry and l l regulatory criteria. Within the panels, considerable effort has been expended by Combustion Engineering, Bechtel, and the other panel vendors 'M to achieve the needed electrical separation requirements. Outside the panels, the cable tray and conduit arrangement is considered to be excellent in terms of meeting electrical separation requirements, providing sufficient access space, general workmanship, and identification legibility requirements. Maintenance records since November 1981 appear adequate and controlled to i the point of turnover to Startup. As installation, modification, and testing work is continuing throughout the plant, the missing separation barrier cover in the Remote Shutdown Panel appears to be an isolated occurrence. In other panels, extensive tagging was observed for temporary modifications needed to support the M Startup program. l l Module calibration stickers within cabinets and panels were current. Improved integration of Combustion Engineering drawings with the Bechtel I cabling diagrams may be necessary to enhance plant operation. Extraction of design configuration i n f o r m a t. i o n, using the Bechtel drawings as a M starting point, is more cumbersome than that encountered at other PWR and l BWR plants. .6 21 y. 3c-1 h' g .~,. Page 6.5-6 HSB: PAR 0003.P06
ussuno in% VI.7 Bottories and Racks M The four main DC batteries, battery chargers, and Vital AC bus inverters were inspectad for electrical separation aspects, fluid levels, termination connections, bolting materials, spacers, mounting M arrangements, and general workmanship and cleanliness. Equipment tha t was inspected is " highlighted" in the following list: DC Batteries and Mounting Racks A, B, C, and D; a 1-E-PKA-F11 1-E-PKB-F12 1-E-PKC-F13 1'-E-PKD-F14 M DC Battery Chargers A, B, C, and D; 1-E-PKA-H11 1-E-PKB-H12 1-E-PFC-H13 1-E-PKD-H14 1-E-PKA-H15 1-E-PKB-H16 j M Vital AC Bus Inverters A, B, C, and D; 1-E-PNA-N11 1-E-PNB-N12 1-E-PNC-N13 1-E-PND-N14 Technical requirements for the batteries, battery chargers, and inverters j contained in procurement specifications 13-EM-050 to Exide, 13-EM-051 to Power Conversion Products, Inc., and 13-EM-054 respectively were reviewed. Each battery was physically inspected for adequate fluid levels, conductor termination connections, bolting materials used, and absence of E battery case cracks. Each battery rack was inspected for battery-to-end plate spacing, battery-to-battery spacers, alignment of frame spring-nuts, and frame welding to the battery room floor imbeds. The location, floor mounting, panel displays, and electrical conduit configuration for each battery charger and Vital AC inverter were inspected. Revisions 0 and 1 of the PM-410 Startup Generic Maintenance Procedure for Station Batteries were reviewed for technical requirements and test acceptance criteria. Records were inspected for each of the four safety-related batteries, such as on-site receiving records, mid-1981 test M results during warehouse storage, and periodic maintenance test result records during construction for the period from February 1982 through September 1983. Installation, in-situ modification, and periodic maintenance records for each battery charger and Vital AC inverter prior to turnover to Startup were also inspected. 6.7.1 Battery Intercell and Terminal Detail Resistance l Despite a PVNGS FSAR licensing commitment on pages 8.3-96 a n s' 8.3-105 to meet IEEE Std. 450-1972, baseline and periodic annual tests of cell-to-cell and terminal detail connection re s is tanc'e have not been 3.4.pio'fthe performed as specified in sections 3.3.3 (2) and IEEE e [. %,.,. -y g ~": " "' e Page 6.7-1 HSB' PAR 0003.P07 l IM WE g- --.s.,_ ~ m. g
[ ZYTOR, INC. M. l Standard. During the inspection, APS indicated that their FSAR commitment to IEEE Std. 450-1972 is limited to those pre-operational tests l identified in Section 14.2 and page 14.B-6 (which do not describe battery resistance tests), and subsequent tests identified in Section 16.3/4.8 (which describe battery resistance testing on a 92 day basis if visible corrosion is detected and on an 18 month basis regardless of visible corrosion). - The following specifications and requirements hr te b e en sto t e d : N Document / Test Condition Cell-Cell ites Battery Res. IEEE Std. 450-1972 Within 20% of value at installation EM-050 Purchase Spec. .00014 ohns .0084 ohms Exide Acceptance / Performance M Test Specification not specified Exide Factory Test Results not available Exide " oral" commitment .000107 ohms .00642 ohms Installation Baseline Tests not available PM-410 Maintenance Procedure not specified FSAR page 16.3/4.8-10 .000150 ohns or within 207, of (later) EG-212.1 Pre-req. Procedure within 20% of average value 32ST-9PK03 Maint. Procedure .000150 ohns .g Preoperational Test Procedure 93PE-1?K02, revision 0 dated October 22, 3,, 1982, requires that Pre-requisite Startup Test Procedure EG-212.1 be completed. This latter procedure requires that intercell resistance values be measured and recorded with corrective action for any cells that exceed 107. o f the average resistance for non-operating batteries or 207. of the average for batteries in service at the time of the test. An absolute value for the maximum intercell resistance at the time of specified in IEEE Std. 450-1972, is not assured battery installation, as by this acceptance criterion. A " baseline" value for cell-to-cell resistance has n o t..y e t b e e n established for any of the four 125 VDC batteries f rod:Thich subsequent degradation can be assessed. Using the present preoperational test schedule for PVNGS, the firs t baseline data will be obtained four years aft T rinitia-1 ba ttery ins tallation. (Finding 6.7.1) Page 6.7-2 M HSB: PAR 0003.P08 l 7,, mm - - e --e=
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i 4MUK, INL. b 6.7.2 Bottery Maintenance Test Doto and Acceptance Criterio i Battery maintenance program requirements, specified in PM-410 revision 1 dated April 5, 1983, exceed the test frequency commitment provided in FSAR Appendix page 8A-8. However, acceptance criteria are h provided only for cell float voltage (not more than.04 volts below the average a n d -2.13 v o l t s minimum) and corrected specific gravity (1.200 to 1.220), but annual test requirements, such as the terminal resistance N, measurements, are not specified. (Observation) 1 [ Bat'tery test data taken in accordance with PM-410 from November 1981 to the present exhibit a number of instances where battery cell voltage variations slightly exceeded the acceptance criteria value. During the inspection, APS initiated CAR S-83-234D to resolve these discrepancies. l These results, identified on page 6.7-4, were accepted rather than being rej ected and then technically justified: a. acceptance criteria of 0.05 volt difference with respect to the cell average is used at times rather than 0.04 volts;
- b. in some instances, cells exceeding the 0.04 volt difference have been accepted rather than being rejected;
- c. ambiguity in battery identification is present on two data sheets;
(
- d. cell voltage acceptance criteria of 2.13 volts minimum is l
listed as 2.19 volts on one data sheet. Battery periodic maintenance records were found at two locations (i.e. APS Maintenance and Bechtel Startup areaa) rather than being controlled at one location. (Finding 6.7.2) In the September to November 1981 period, APS Maintenance took battery data using a work order and data sheet. No procedure or acceptance any justification provided that the data was criteris were used, nor was indeed acceptable. (Finding 6.7.3) During the responsibility transition for battery maintenance from APS Maintenance to Bechtel Startup, battery data was not taken for the months of December 1981 and January 1982. APS initiated CAR S-83-233D during the inspection to technically assess these data omissions. (Finding 6.7.4) 6.7.3 Battery Rack Spring-Nut Alignment Battery rack spring-nuts were found improperly installed near cell 24 of battery 1-E-PKC-F13A and near cell 58 of battery 1-E-PKA-F11. NCR to re-align d is p[o si tio n SM 2889 has been prepared by APS with an interim M ( the spring-nuts. (Observation) b l
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. D[.~ Page 6.7-3 HSB: PAR 0003.P09 M ii- [
ZYTOR, INC. g g.- STATION BATTERY TEST DATA DISCREPANCIES BATTERY DATE DISCREPANCY 5 1-E-PKA-F11 05-24-82 CELL 30 VOLT >.04 DIFFERENCE CELL 45 VOLT).04 DIFFERENCE 1-E-PKA-F11 06-18-82 CELL 29 IDENTIFIED AS 39 1-E-PKA-F11 07-16-82 CELL 60 VOLT >.04 DIFFERENCE 1-E-PKA-F11 07-30-82 CELL 17 ACCEPTED) 04 DIFF. 1 CELL 29 ACCEPTED).04 DIFF. f e 1-E-PKA-F11 C1-11-83 CELL 02 ACCEPTED >.04 DIFF. 1-E-PKA-F11 04-18-83 CELL 45 VOLT >.04 DIFFERENCE 1-E-PKA-F11 06-16-83 CELL 17 ACCEPTED).04 DIFF. CELL 49 ACCEPT 2D>.04 DIFF. CELL 57 ACCEPTED).04 DIFF. 1-E-PKB-F12 07-01-83 CELL 45 VOLT >.04 DIFFERENCE CELL 60 VOLT >.04 DIFFERENCE 1-E-PKB-F12 07-14-83 CELL 01 VOLT).04 DIFFERENCE CELL 30 VOLT >.04 DIFFERENCE CELL 45 VOLT).04 DIFFERENCE CELL 60 VOLT).04 DIFFERENCE E 1-E-PKB-F12 11-04-82 UNCLEAR BATTERY DESIGNATION BETWEEN -F12 AND -F14 1-E-PKB-F12 09-21-82 CELL 01 ACCEPTED).04 DIFF. E CELL 20 ACCEPTED).04 DIFF. CELL 45 ACCEPTED >.04 DIFF. CELL 54 ACCEPTED).04 DIFF. P] ACCEPTANCE CRITERIA.05 VDC L'J' 05-21-82 CELL 01 VOLT).04 DIFFERENCE 1-E-PKB-F12 1-E-PKB-F12 05-04-82 CELL 01 VOLT >.04 DIFFERENCE g-, CELL 45 VOLT >.04 DIFFERENCE [~" 1-E-PKB-F12 04-08-82 ACCEPTANCE CRIT 2.19 VOLTS i 1-E-PKC-F13 04-18-83 CELL 24 ACCEPTED >.04 DIFF. CELL 51 ACCEPTED >.04 DIFF. ~~ CELL 58 ACCEPTED).04 DIFF. h,a 1-E-PKD-F14 06-02-83 CELL 30 VOLT >.04 DIFFERENCE m 1-E-PKD-F14 10-18-82 CELL 01 VOLT).04 DIFFERENCE b 1-E-PKD-F14 09-23-82 CELL 04 VOLT >.04 DIFFERENCE CELL 12 VOLT).04 DIFFERENCE CELL 16 VOLT).04 DIFFERENCE CELL 25 VOLT >.04 DIFFERENCE I] CELL 26 VOLT >.04 DIFFERENCE "~J CELL 36 VOLT).04 DIFFERENCE CELL 48 VOLT >.04 DIFFERENCE F~"l CELL 51 VOLT).04 DIFFERENCE Ld CELL 58 VOLT).04 DIFFERFNCE CELL 59 VOLT >.04 DIFFERENCE c7 ACCEPTANCE CRITERIA.05 VOLT [_] 1-E-PKD-F14 06-02-82 CELL 60 VOLT).04 DIFFERENCE L 1-E-PKD-F14 02-26-82 CELL 07 ACCEPTED).04 DIFF. ,,. a g,, CELL 22 ACCEPTED >.04 DIFF. n.K2fk ] CELL 24 ACCEPTED).04 DIFF. H ',' y, CELL 26 ACCEPTED).04 DIFF. [f ?? , PT]p"" CELL 54 ACCEPTED).04 DIFF. CELL 57 ACCEPTED).04 DIFF. Page 6.7-4 I E HSB PAR 0003.P10
I ZYTOR, INC. 6.7.4 Ba ttery Load Capacity Test Results I IEEE Std. 450-1972 requires a factory or initial installation acceptance test at a specific discharge rate and duration, and a test of battery capacity within the first two years of I performance service and at. periodic intervals afterward. Battery "C" did not quite meet the required minimum cell voltage criterion during the factory test. Bechtel issued SDDR 2763 to accept the battery with a s ta ted dis posi, tion that the tests would be performed at the PVNGS. The November 1983 4 E scheddled battery preoperational test using procedure 32ST-9PK03 requires .o 2 hour capacity test using the load profiles contained in the EM-050 battery purchase specification. These test conditions closely-approximate, but do not entirely envelope, the comnitment provided in FSAR Table 8.3-6. However, section 4.9.1.3 of the 13-EM-050 purchase specification requires that written documentation and certified test
- I reports be provided by the vendor to demonstrate that the battery meets the PVNGS load profile requirements. (Finding 6.7.5)
Variations in the acceptance test and perf ortuance test requirements for the "A" and "B" batteries were noted during the inspection: IEEE Std 450-1972(acceptance) rating rating installation i ] (performance) rating rating within 2 yrs. then 60 months I JJ EM-050 Purchase Spec. Load 2 hours once profiles N L,3 Exide Acceptance / Performance Test Specification 605 amp. 2 hours once >} ^~ Exide Factory Test Results 605 amp. 2 hours once g PM-410 Maint. Procedure none .none none FSAR 16.3./4.8-10(service) loads duty 18 months none none 60 months (capacity) tw EG-212.1 Pre-req. Procedure none none none 93PE-1PK02 Preop Test Proc. load 2 hours once profiles .. g.. 32ST-9PR03 Maint. Procedure load 2 hours 18 months Ed profiles r l .y 9: ~ 225 amp. 8 hours 60 months ~ . M,32ST-9PK04 Maint. Procedure l 9 1 L. HSB: PAR 0003.P11 M Q*
ZTTOR, INC. 6.7.5 Battery, Charger, and Inverter conclunions The number of relatively small individual problems identified with the batteries during the past several years could easily be a cause for regarding their ability to perform adequately in the future. One a concern deviation is the decision to obtain intercell and terminal detail resistance baseline values several years after the initial installation, as described in Finding 6.7.1. To compensate for this elapsed timea period, the Noverker 1983 acceptance criterion for the "ba'seline" # resis'tance measurements should be closer to the recent Extde oral commitment of 107 micro-ohms than the APS procedure maximum value of 150 micro-ohms. Turnover of battery maintenance to Bechtel Startup in late 1981 was evidently not skillfully executed by either party. Once the Bechtel Startup group gained control of this situation, maintenance records from February 1982 indicate that adequate oversight is being applied to minimize battery degradation with time. The observed battery data discrepancies shown on page 6.7-4 should prove to be technically insignificant; nevertheless, acceptance of test data outside of acceptance criteria limits and the total absence of technical Il justification statements on the data sheets remains a cause for concern. y Problems noticed with APS Maintenance practices during the fall of 1981 r~' with regard to procedures and acceptance criteria appear to have been L _a] fully resolved by the Pre-requisite and Preoperational test procedures now in place. The controls presented by APS QA and Maintenance groups f during the inspection appear sound and complete. Planned periodic testing fq using the 2 hour load profile for battery capacity tests is considered to '( be excellent. ["] Physical inspection of the batteries, chargers, and AC inverters '-J indicated that the installation was satisfactory. Electrical separation and conduit routing for each of the four divisions was also satisfactory. p~ The battery cases were free from cracks observed at another plant, and L_g the battery rack installation is considered acceptable. The probability of battery, charger, or AC inverter inadequacy is judged y_q ) l to be extremely remote based on the results of this inspection given that ""J the planned pre-requisite and preoperational test results confirm that no degradation has taken place since installation. I .LJ m L__d ......~ .' JId$${ r~'l ' ' ' ~ L..d ~ r-;, L~sj Page 6.7-6 HSB: PAR 0003.P12 l Illi
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ZYTOR, INC. Roforences No. Document Type Title / Subject Number Rev Date 6.01 BECHTEL DWG CONDUIT / TRAY NOTES 13-E-ZAC-050 16 06-06-83 6.02 BECHTEL DWG SEPARATION GUIDE 13-E-ZAC-077 2 06-06-83 6.03 BECHTEL P&ID CHEM / VOLUME CONTROL 13-M-CHP-002 9 08-12-83 6.04 BECHTEL P&ID SAFETY INJECTION 13-M-SIP-001 9 06-08-83 it '6.05 BECHTEL P&ID HVAC CONTHT BLDG 13-N-HCP-001 10 0,8-02-83 g; 6.06 BECHTEL ISO HPSI PUMP DISCH/RWT 13-P-SIF-203 12 ILLEGIBLE" 6.07 BECHTEL MAIN SINGLE LINE 13-E-MAA-001 6 G8-06-83 6.08 SINGLE LINE UNIT SINGLE LINE 13-E-MAA-002 7 09-24-82 6.09 DIAGRAMS 4KV SWITCHGEAR 13-E-PBA-001 5 12-02-82 6.10 480V MCC PHA-M33 13-E-PHA-003 9 ILLEGIBLE l: 6.11 480V MCC PHB-M36 13-E-PHA-006 8 ILLEGIBLE 6.12 120V DP PNA-D25 13-E-PNA-001 6 07-06-83 f 6.13 120V DP PNB-D26 13-E-PNA-002 5 09-23-82 6.14 BECHTEL SAFETY INJ. PUMPS 13-J-SIL-009 0 07-07-83 6.15 CONTROL SAFETY INJ. VALVES 13-J-SIL-010 0 07-20-83 6.16 LOGIC DIAG. SAFETY INJ. VALVES 13-J-SIL-013 0 07-22-83 6.17 SAFETY INJ. VALVES 13-J-SIL-016 0 07-07-83 6.18 BECHTEL SI HPSI FLOW TO RC 13-E-SIB-009 4 ILLEGIBLE I 6.19 ELEMENTARY SI HPSI FLOW TO RC 13-E-SIB-010 4 ILLEGIBLE 6.20 DIAGRAMS SI HPSI FLOW TO RC 13-E-SIB-011 4 ILLEGIBLE 6.21 SI HPSI FLOW TO RC 13-E-SIB-012 4 ILLEGIBLE 6.22 HPSI RECIRC TO RWT 13-E-SIB-016 6 ILLEGIBLE l 6.23 HPSI RECIRC TO RWT 13-E-SIB-018 2 05-05-83 6.24 RWT TO HPSI VALVES 13-E-CHB-029 4 05-23-83 6.25 HPSI PUMP P02 13-E-SIB-001 4 ILLEGIBLE 6.26 HPSI PHP DIS VALVE 13-E-SIB-039 2 03-11-83 6.27 BECHTEL 125VDC/VITL ONELINE 13-E-PKA-001 2 03-24-82 6.28 125VDC 125VDC CC PKA-M41 13-E-PKA-002 5 11-12-82 6.29 SINGLE 125VDC DP PKA-D21 13-E-PKA-003 6 12-10-82 6.30 LINE 125VDC CC PDC-M43 13-E-PKA-004 6 ILLEGIBLE 6.31 DIAGRAMS 125VDC CC PKB-M42 13-E-PKA-005 5 12-02-82 6.32 125VDC DP PKB-D22 13-E-PKA-006 6 06-08-83 6.33 125VDC CC PKD-M44 13-E-PKA-007 6 08-25-83 6.34 125VDC BRKR PKA-F11 13-E-PKB-001 5 12-08-82 6.35 125VDC BRKR PKC-F13 13-E-PKB-002 5 ILLEGIBLE 6.36 125VDC REV STARTER 13-E-PKB-003 1 10-11-79 6.37 480VAC BATT.CHGRS 13-E-PKB-004 7 02-07-83 6.38 BECHTEL CVCS INST LOOP 13-J-CHE-0C3 5 06-13-83 6.39 INSTRUMENT HPSI LOW FLOW ALARM 13-J-SIE-0A0 3 08-04-83 l 6.40 LOOP SAFETY INJECTION 13-J-SIE-079 1 04-01-83 6.41 DIAGRAMS REACTOR COOLANT SYS 13-J-RCE-064 5 08-01-83 6.42 HVAC SYSTEM-CNTMT 13-J-HCE-061 4 03-11-83 6.43 CABINET' POWER DIST 13-J-ZZE-051 1 05-16-83 6.44 BECHTEL PROC. PROT. CAB. Al B-14273-412-502 3. ILLEGIBLE 4 6.45 WIRING PROC. PROT. CAB. B1 B-14273-412-504/49.'nIO-03-82 6,46 CONNECTION REMOTE SHUTDOWN PNL B-14273-412-515 2 "'06-12-82 5 6.47 DIAGRAMS MISC. PROC. CABINET C-14273-412-501 3 05-17-83' C Page 6.7-7 } HSB: PAR 0003.P13 ( 4 = =
r,- ZYTOR, INC. Personnel Interviewed L. Souza ~ APS Construction QA g, S. Penick APS C o n s t-ru c t i o n (A 1 ~ W. Wessala Bechtel Construction M. Alexander Lead Elec Engineer Bechtel Construction R.L. Anderson 'Bechtel Construction J. Kearns Bechtel Construction f
- 1. Williams Maintenance Engineer Bechtel Construction J. Black Resident Engineer Bechtel Construction K.
Hurty Resident Engineer Bechtel Construction E.C. Laner Resident Engineer Bechtel Construction i V. Bingham i G. Aasen Resident Engineer Combustion Engineering D. Boling APS Operations I J. Kolski Startup QA Supervisor APS Startup D. Deruiter Planner-Coordinator APS Maintenance L. Barlow Elec.Haint. Supervisor APS Maintenance C. Russo Mgr.,0perations QA/QC APS Quality Assurance I C. Lewis Quality Ing'g. Supervisor APS Quality Assurance, 'g J. Behm Quality Engineer III APS Quality Assurance fW l N. Howe Operations QC Supervisor APS Quality Assurance l l . g. v u m h5W:;' =m x l .'.S$p%d- ~ . cAffA;F Page 6.7-8 HSB hAR0003.P14 l t s - ^ - - - - - 9 ,em*K
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6 C ABL E PULL C A LCUL ATION NJ MBER ~ Ni YD W F/ I ' LR lONW t T MAXIMUM ALLOWABLE POLLING TENSION iJA )04 6 / 1 d.. M i l 8 DYNAM0 METER OR TENSIONOME TER READING OM i d l i 9 ACTUAL PULLING TENSION laNS t [t DYttAMOMETER OR TENSIONOME TER S/N_ IJ 11 CABLE ENDS SE ALED - AS RE QUIRED . Q[ i 10 DN% I CAL.,_DATE,_ ,lo N W r
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f SSINS No.: 6835 8 IN 83-23 VWEnovo4.A V UNITED STATES d NUCLEAR REGULATOP,Y C')MMISSION OFflCE OF INSPECTION AND EllFORCEMENT WASHINGTON, D. C. 20555 April 25, 1983 IE INFORMATION NOTICE NO. 83-23: IN0PERABLE CONTAINMENT ATMOSPHERE SENSING SYSTEMS Addressees: i I All nuclear power reactor facilities holding an operating license (OL) or constructionpermit(CP). Yrpose: This information notice is being issued to remind all licensees of the impor-tance of assuring that procedures are',both properly developed and carefully followed. The instances cited relate 'to the containment system, an important element in the " defence-in-depth" appro,ach to nuclear safety and are of partic-ular concern because some had apparen.tly existed for several months without detection. Description of Circumstances: (., 3 Seven instances have been compiled since April 1981 that indicate insufficient licensee management attention is being given to maintaining containment in-tegrity, and to the operability of equipment related to the containment function. At Lacrosse Nuclear Generating Station on two separate occasions in April 1981, a containment high-pressure sensing switch was temporarily isolated while the plant was at power, thus defeating automatic emergency core cooling system actuation. A proposed design change was being implemented without proper re-view and authorization. Subsequently, it was determined that under 10 CFR 50.59, the change should not have been made without concurrence by the Nuclear Regu-latory Commiss-ion. At Oconee Nuclear Station, in March 1982, an NRC inspector found that a pipe cap had not been reinstalled on a test connection to a containment pressure sensing line, as required by the relevant test / calibration procedure last performed in July 1981. As a result, containment integrity had been violated for that inter-val, and the sensing system (although operable) was degraded. Containment pressure as sensed by the system could be significantly lower than actual containment pressure. At Dresden Unit 2, there is a local sight (gage) glass on the side of the sup-pression pool to show the level of the water in the pool. In~ October 1982, the g: y-
7 IN 83-23 April 25, 1983 Page 2 of 3 i h licensee reported finding the upper isolation valve and the vent velve open. This violated containment integrity, and allowed free communication between the inerted atmosphere of the suppression pool and the outside atmosphere. In fact, both the upper and lower isolation valves should be closed, except when cali-brating other level-sensing devices, while shut down. At Kewaunee Nuclear Station, the licensee reported in October 1982 that all con-tainnent pressure-sensing lines were found to have pipe caps installed, thereby defeating the entire containnent pressure-sensing systems, including alarm and emergency core cooling functions. The licensee believes the caps were improperly left in place after required testing and calibration about five months earlier. I At Arkansas Nuclear One on December 16,'1982, during performance of routine re-fueling surveillance of the reacter building pressure transmitters, the licensee disco'!ered that the inlet ports on two transmitters were blocked with brass pipe plugs. One of the two inoperable transmitters provide an input to a recorder; however, the other instrument provides a signal to one of three engineered safe-guards actuation system (ESFAS) safety channels. With this transmitter input plugged, the ESFAS logic for reactor building high pressure was reduced from a 2 out of 3 to a 2 out of 2 trip logic req'uired for the initiation of engineered safeguards. It was determined that the plugs were installed on February 20, 1981, as a prerequisite for a containment integrated leak rate test and remained in-stalled until their discovery on December 16, 1982 during the next refueling out-age. The licensee attributed the specific cause to use of an inadequate temporary test precedure change which allowed plugs to be installed in the pressure trans-t mitters but did not contain a step specifically requiring their removal. At Calvert Cliffs Nuclear Power Plant on June 18, 1982, an NRC inspector and licensee representative were examining containment system boundaries of Unit 1 in preparation for a containment integrated leak rate test. They discovered two of the four safety-related containment pressure sensing lines were isolated with pipe caps inside containment, thus deactivating containment pressure monitoring instruments which provide protection signals to the safety systems. A review of records and logs from the prev 1ous operating cycle revealed that this inoperable condition did not exist prior to the last refueling outage. The licensee reviewed records and conducted an investigation but was unable to detennine who installed the pipe caps; when they were installed; or with what authorization. It was how-ever assumed that they were installed by mistake during the prior outage, in each of the above instances, in normal operation there is little difference between containment pressure and ambient atmospheric pressure. For pressure differences of the magnitude expected in normal containment system operations, verification techniques such as trend plott.ing of averaged output values may be beneficial to supplement visual verification of individual component status. At Salem Nuclear Statien, on October 17-18, 1982, the licensee found during con-tainment purge operations that radiation monitor sensing lines, which provided I high radiation level automatic containment isolation signals, had been temporarily capped while making a design change, and the caps had not subsequently heen l G n-e r-
l ill 83-23 April 25, 1983 9 Page 3 of 3 h removed as required. The work had been performed during a refueling outage which terminated on April 11, 1982. i Systems for sensing airborne radioactivity typically include a blower or air pump to extract a sample of the air being monitored and direct it through or past sensors. For the very low levels of activity normally expected, some technique is required for integrating total activity over a known time interval. To achieve acceptable accuracy of calibration, the actual flow (quantity of air in the total sample) must be known. Periodic observation of the flow measuring device provides a simple means of verifying this aspect of system operability, and would have detected the capped lines at Salem. Although all the examples cited above involve sensing of containment atmosphere conditions, (pressure and radioactivity) and the licensee event reports do not in each case identify why the anomalous condition existed undetected for so long a time, the NRC staff is of the opinion that inadequate surveillance procedures, or inadequate 1:nplementation of the procedures, or both, were the underlying cause(s) of the situations. Further, a variety of other instances have appeared in licensee reports indicating that su'rveillance of operability of other safety-related systems could be improved. f No specific actions are required of anyllicensee by this Information Notice. If you have any questions regarding this' matter, please contact the Regional Administrator of the appropriate NRC Regional Office or this office. 2 dwar . Jordan, Director Divi i of Emergency Preparedness an Engineering Response Office of Inspection and Enforcement
Attachment:
List of Recently Issued IE Information Notices Technical
Contact:
J. B. Henderson (301) 492-9654 ,y n. .~.4a 4 _v..
Attachit.ent IN 83-23 April 25, 1983 LIST OF RECEf1TLY ISSUED IE It! FORMAT 10t1fl0TICES .g Information Date of flotice flo. Subject Issue Iss e d to 83-01 Ray Miller, Inc. 4/15/83 OL, CP, Nuc. Fuel Supp. I Cycle Lic., Cat. B, Pri.1 Ma t. Lic. 83-22 Boiling Water Reactor 4/22/83 All pcwer reactor Safety / Relief Valve Failures facilities holding an OL or CP. 83-21 Defective Emergency - Use 4/15/83 All power reactor Respirator facilities holding an OL or CP, research & test reactors, fuel cycle licensees, & Priority I naterial licensees. 83-20 ITT Grinnell Figure 306/30,7 04/13/83 All pnwer reactor Mechanical Snubber Attach-facilities holding ment Interference an OL or CP A 83-19 General Electric Type HFA 04/05/83 All power reactor. (# Relay Contact Gap and Wipe facilities holding Setting Adjustments an OL or CP 83-18 Failures of the undervoltage 04/01/83 All power reactor HFA trip function of Reactor facilities holding Trip System Breakers an OL or CP 83-17 Electrical Control Logic 03/31/83 All power reactor Problem Resulting in Inoper-facilities holding able Auto-Start of Emergency an OL or CP Diesel Generator Units 83-16 Contamination of the Auburn 03/30/83 All Material Steel Preperty with Cobalt-60 licensees 83-15 Falsified Pre-Employment 03/25/83 All power reactor ) Screening Records facilities holding I an OL or CP 83-14 Deuatered Spent Ion Exchange 03/21/83 All power reactor Resin Susceptibility to facilities holding Exothernal Chemical Reaction an OL or CP OL = Operating License () CP = Constructinn Pernit
NRC 2 ISEG GARRETT 123556T890 IEN IEN 83-22 Bh4 SAFETY / RELIEF W ALVE FAILURES 02/09/33 05/07/83 p C6/3?/M3 06/06/83 o LRIGIhATCk ISEG ELyoc STATUS CCI COMMENTS p. EQ ID EC DESC STEP 01 REVIEW FOR APPLICABILITY TO PWNGS ISEG GARRE TT 06/06/63 Go/co/83 3 06/06/83 06/06/83 STATUS COM CGNMEhTS l 1,,. 1234567890 IEN I EN 8 3-23 INOPERABLE CONTAINMENT AIMOSPHERE SENSIN ISEG FERNARI = 06/01/63 06/08/83 NRL 4 b 5f5 TEM 5 11/01/83 n ie, ~ DRIGINATOR ISEG SP INN ATO STATUS ACT CGmMENTS n tQ ID EQ OESC [ STEP 1 DISTRIBUTED TO OPS 70 VERIFY IHEIR AWARE OPS Y OUNGE R 06/08/d3 Go/08/83 NESS GF PROBLEM. 11/ ul/m3 n SI AIU5 ACT : COMM ENTS sitP g uteut>Ito Mtv A th OF SURVEILLANLE PkOGEDu ENGR ROMAN 06/1*/sJ 0o/14/83 kES BE MADE TO ENSURE ADEQUACY OF PROCED 07/15/83 07/11/83 UAE. STATUS COM COPMEATS 1234567890 IEN IEN 83-26 LOOSE PARTS IN THE 'SECDNDARY SIDE OF SIE ISEG GONSOWSKI NRC 2 AM GENERATORS AT PRESSURIZED WATER REACT !* 06/01/83:04/26/83' i i. 09/30/83 DR5 ChlGINATbM ISEG sPIhNAIO 1 STATUS ACT CCMMtNTS ORIG SCHED COMP 04/1S/83. EQ ID EQ DESC [ STEP 1 REV IEW INPO RECOMMENDATIONS OF SOER 82-l' ISEG GONSakSt 1 ~ 06/24/83 06/26/83' l 2 AND RENEW THCSE COMMITMENTS.THIS IEN W C9/30/83 ILL AUDMthh SULM 52-JZ AG i lON ITEMS. 51AIU5 ALT CLAMEhT5 Gd!G 50HED COMP 03/08/m3. l a 1434567890 IEN IEN 83-25 STAND 8Y GAS TREAIMENI SYSTEM HEATER HIGH ISEG FERRARI* 06/01/83 06/15/83 -~~hML 4 ILMPtpAIUnt I RIP b tJ PUIN I AUJub5MU43 ,0T/15/83 De/Ab/83 g t ORIGINATOR' ISLG ' SPINNATE. 3-(f
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STATUS COM COPMENTS ~ ' tQ ID LQ DE5G .i STEP 1 DETERMINED NOT APPLICABLE BECAUSE PVNGS ISEG GROSS 06/15/d3 0e/15/83 U:Jt h NLI HAVE 5YhttM. DI53R15UTtD FUR I s -406/15/83 06/15/83-r <.1. .g NFO 10 MNIC DUE 10 SIMILAR HVAC SYSTEMS 'STAIUS COM' COPMENTS e4 l* s' l ,}}