IR 05000348/1992035

Insp Repts 50-348/92-35 & 50-364/92-35 on 921208-930108. Violations Noted.Major Areas Inspected:Operations,Maint, Surveillance,Licensee self-assessment,emergency Preparedness & Action on Other Previous Insp Findings

ML20128A721
Person / Time
Site:	Farley
Issue date:	01/15/1993
From:	Cantrell F, Maxwell G, Morgan M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20128A676	List: IR 05000348/1992035 ML20128A671 ML20128A682
References
50-348-92-35, 50-364-92-35, NUDOCS 9302020295
Download: ML20128A721 (11)

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Report Nos.: 50 348/92-35 and 50 364/92-35 Licensee: Southern Nuclear Operating Company, In P.O. Box 1295 Birmingham, AL 35201-1295 Docket Nos.: 50-348 and 50-364 License Nos.: NPF 2 and NPF 8 facility Name: farley 1 and 2 Inspection Conducted: December 8,1992 - January 8,1993 Inspectors: b 'T? MI N' 15 p B. F. REwelT, $cidtf 11esident Inspector Dil e~M[gne'd

@ P .T O E k M. J. M 7ga 7 Resfhentj inspector (f arTey)

i/mA2 Date signi3 Approvedpy: Mh' / // f3 p . St Q6ntrell, Chief Da e igned Reactor Projects Section IB Division of Reactor Projects SUMMARY Scope:

This routine, resident inspection involved on-site inspection of operations, maintenance, surveillance, licensee self-assessment, emergency preparedness, and action on other previous inspection findings. Deep backshifts were performed December 13, 1992 and January 8, 199 Results:

This inspection identified a violation regarding the procurement-and control of oils and other lubricants used in safety-related applications which resulted in a misidentified barrel of Texaco "R&0 68" oil being used in-equipment where Texaco "R&O 32" oil was specified, paragraph.8. On December 9, the licensee conducted an annual emergency preparedness exercise, paragraph 6. On December 13, a Unit I reactor trip occurred during surveillance testing, due to erratic feedwater regulation valve operation, which resulted in steam flow exceeding feed flow and a subsequent low level condition in the "lC" steam generator' paragraph 3.a. On December 16, the wrong data table was used for data input into nuclear instrumentation (NI)

channel "N-43". A non-cited violation-(NCV) was identified for this event, paragraph 5.b. Also, on December 16, a plant operations review' committee meeting was attended by the resident-inspectors, paragraph 7. During the inspection period, escalated pressurizer (PZR) code safety valve tailpiece-temperatures were continuing to be observed for the Unit 2, "B" code safety, paragraph PDR .ADOCK 05000340

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Except as noted, no deviations or other violations were identifie Results  !

of this inspection indicate that actions by management, operations, l maintenance and other site personnel were adequat l i

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PEPORT DETAILS  !

! Persons Contacted l

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Licensco Employees

• Bayne, Supervisor Safety Audit and Engineering Review R. Coleman, Modification Manager

• L. Enfinger, Administrative Manager S. fulmer, Superintendent, Operations Support

• R. Hill, General Manager farley Nuclear Plant - .

• J. McGowan, SNC Manager Safety ~ Audit and Engineering Review >

• D. Mansfield, SNC Manager - NHS M. Mitchell, Superintendent, Health Physics and Radwaste

• C, Nesb'itt, Operations Manager

• J. Osterholtz, Assistant General Manager - Plant Support

• L. Stinson, Assistant General Manager - Plant Operations ,

' Thomas, Maintenance Manager L. Williams, Training Manager  :

B. Yance, Systems Performance ~ Manager ,

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• Attended the exit interview Other licensco employees contacted included, technicians, operations personnel, security, maintenance, l&C and office personnel, f. S. Cantrell, Chief, Section IB was on site December 7-9, 1992, to_ ;

review resident inspection activities and discussion with licensee -

personne During the week of December 14 - December 18, a representative from Japan's Ministry of Industry and Trade, M. Mizuno, observed site ,

resident inspector activitie Acronyms and initializations used throughout this report are listed in the last paragrap . Plant Status Unit 1 Status  ;

Unit 1 operated at approximately 100. percent power for most of the reporting period. On December 13,'an automatic reactor trip ;

occurred during surveillance testing due to erratic feedwater regulation _ valve o)eration, which resulted in steam flow exceeding feed flow and a su) sequent low water level in the "lC"' steam generator. The reactor was returned to power (critical)

December'14 at 1:3S a.m., achieved Hodo 1 at 8:13 a.m. and placed on the grid at:ll:52 a. . -

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2 i Unit 2 Status Unit 2 operated at approximately 100 percent power for most of the '

reporting perio < NRC/ Licensee Meetings and Inspections ,

During the week of December 7, Region 11 Emergency Preparedness :

(EP) personnel conducted a routine inspection of the licensee's !

annual EP exercise. Results of the inspection are documented in -

Inspection Report 50-348,364/92-3 On December 7 and 8, Region 11 Radiological Protection personnel conducted a special follow up inspection of-a reported high TLD (exposure) reading of licensee personnel (a facility welder). ,

Results of the inspection are documented in Inspection Report 50 348,364/92-3 . Operational Safety Verification (71707)

The inspectors conducted routine plant tours to verify licensee requirements and commitments were being implemente The inspection 1 tours included review of site documentation, interviews with plant r personnel and an on-going evaluation of-licensee self-assessmen Reactor Trip During I&C Surveillance Testing - Unit 1

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During I&C surveillance tnsting, on December 13, at 2:57 a.m., the i Lnit I reactor automatically tripped on 25 percent S/G water level coincident with low feedwater (FW) flow to steam flow in the "10" S/G. %e inspectors reported promptly to the site and observed ongoing activitias associaRd'with the trip, i

The licenser determined that FW flow channel number 3 was placed '

in " test" as part of the surveillance at 2:42 a.m.. .At 2:57 a.m., '

"lC" S/G low FW flow channel number bistable flashed and FW flow to all S/Gs began to oscillate. The unit oporttors took sanual ,

control of "A" and "C" FW regulating valves and attempts to increase flow io restore all S/G levels were not successful. The reacter trippeu when "C" S/G level reached 25 percent levet An evaluation cf the system logic revealed that by placing the FW flow channel number 3 in " test , a FW flow less than steam flow signal and a 25 percent S/G level .tr% sapoint was ir serted. The flashing channel 4 low FW flow was caused bv a blohn (use in the ~. '

steam flow selector switch relay card. When channel 4 was selected ,

as the controlling channel, the signal was not actually switched"

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to channel 4 but instead remained selected to channel 3. When the- !

assotiated channel 3 controlling relay card was removed, as'part of the surveillance test, a channel 3 steam flow signal was lost and the feedwater regulating- valves closed. This' loss of FW flow

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l" contributed to the loss of the "10" S/G water leve _ . - - _ . - , _ _ _ __ - . . . _ _ _ _

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The blown fuse and relay cards were replaced, channels 3 aad 4 were returned to service, the reactor was returned to power and the unit placed on the grid. The licensee has drafted an LER to document the circumstances and conditions related to the event, plR Code Safety Valve liigh lailpiece Temperature Update Unit 2 (Ifl 50-364/92 25 01)

During the inspection period, escalated pressurizer (p2R) code safety valve temperatures were continuing to be observed by the inspectors, (see inspection Report 50 348,364/92-25,- paragra)h 3.b.). Since the initial temperature excursion, operations las conferred with the NSSS and valve vendors and determined that a small " wisping" action is probably occurring from the valvo. Only-a very small amount of measurable RCS leakage has been note The inspectors have noted that operations continues to record peak temperature excursions and trend tailpiece temperatures for all code salitic Thc inspectors will continue.to monitor licensee actions for this even This item continues to be ope ,

No deviations or violations were identified in this area. Results of inspections in the operations area indicate that operations personnel conducted assigned activities in accordance with applicable procedure . Monthly Maintenance Observation (62703)-

The inspectors reviewed various licensee preventative and corrective maintentnce activities,-to determine conformance with facility

procedures, work requests and NRC regulatory requirement portions of the following maintenance activities wcre observed:

o MWR-268796; "2C" D/G output breaker charging spring motor' running-continuously - investigate and repair-The inspectors noted that the breaker latch s) rings'were replaced'

and that the drive unit.was checked. ribe brea<er drive unit required replacement and maintenance personnel' replaced-the overall unit with a refurbished-breaker, inspectors noted that work performed was satisfactory and in accordance.with direction contained in the MW o MWR-238200; "10" D/G service water line-leak - investigate and repair (Note: part-of scheduled "lC" D/G maintenance)

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Inspectors observed maintenance trouble-shooting and replacementf efforts associated with an associated leaking SW pipe _ expansion (bellows) joint. The leak was found in the area of the bellows joint. A "new" expansion joint was obtained and the "old" joint

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4 l replaced. Inspectors noted that work performed was satisfactory- i

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and in accordance with directions contained in the MW +

o MWR-202836; Replace valvo delivery springs on fuel injection 1 pumps; "20" D/G (Note: Part of scheduled "2B"-D/G ~  ;

maintenance)

Inspectors obser' ad re)lacement of the valve delivery s) ring The inspectors noted tlat "new" springs were properly 03tained and  ;

the "old" springr were discarded. Work parformed was satisfactory ,

and in accordance with directions contained in the work reques i o WOO 382843; Replace packing and "0"-rings on fuel injection pump fuel return lines "2B" 0/G (Note: part of scheduled ,

• 2B" D/G maintenance) ,

inspectors observed portions of this work order being performed,

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This maintenance is a five-year preventative mt.intenance item, inspectors noted that proper materials were obtained from the a warehouse and that fuel lines were : loaned prior to packing replacement. Work performed was satisfactory and in-accordance  !

with directions contained in the work order, ,

No deviations or violations were identified in this area. The results of inspections in the maintenance area indicate that botn operations and_ ,

maintenance personnel conducted assigned activities in accordance with-applicable procedures, 4 Monthly Snrve111acco Observation (61726)  ;

Inspectors witnnsmi surveillance test activities performed on safety-related systems and components, in order to verify that such activities were performed in accordance with facility procedures and NRC regulatory and licensee technical specification requirements,

' The following surveillance activities were observed: l o 1-STp-1.0;. Operations-Daily / Shift Surveillance Requirements ~

2-STP-1.01 Modes 1, 2. 3, Land 4 Inspectors routinely observed operator activities while

, parmneters were monitored, documented and evaluated, o 1-STP-226.18; "BlG". Sequencer.0perability Test inspectors observed 1&t technician performance- for portions of the test- and responses to Agastat relay performanc s o 1-STp 33.lA, Train ?A" Solid State prot'ection System Test

(SSpS)

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inspectors observed operator performance of SSPS testing ard, testing of logic setups, trip functions and data recordin l o 1 STP 80.1; Diesel Generator "lC" Operability Test '

Inspectors evaluated the performance, after scheduled maintenance, of load testing on the D/G, increasing and  :

decreasing electrical loads and maintaining the loads for approximately one hou Wrong Data Used for input !nto Nuclear Instrumentation (NI) Power Range (PR) Channels "H 41" and "N 43" Unit 2

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The inspectors, after reviewing FNP Maintenance Incident Report IR

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92 035 and citer interviews with the maintenance superintendent the 1&C supervisor, noted the following. On December 16, during performance of a surveillance test on PR NI channel "H-43*, values lis^.ed for the gain potentiometer ()ot) settings were different from the required values given in tie Unit 2 Plant Curve Boo .

As part of surveillance STP228.7, "NI System PR Channel N43  :

Calibration and functional Test", the I&C technician was required to obtain gain pot setting values from the~ Unit 2 Plant Curve Book -

(02 PCB), curvo "71B". The unit operators who routinely use. data from the U?-PCB, curve "71A" (nni curve "71B"), had crossed out curva "71B" in the U2 PCB. The 1&C technician mistakenly assumed that the' crossed out curve had been superseded by the unmarked curve "71A" and used values listed in the curve in the test data sheet ;

NI channel "N-43" remained in this erroneous configuration for approximately two hours, until the error.was noted in a post work review by the job foreman. The channel was immediately taken out-of service and the surveillance conducted again using the correct values listed-in curve "71B". The-prompt review of the work by the job foreman was resoonsible for the quick identification of this erra *

The technician involved was'" coached". The maintenance superintendent initiated extensive procodural changes that-include aapropriate gain pot values within the procedure.1hese actions s1ould minimize the possibility of errors when transposing data-from the U2-PCB to thi test data sheet After reviewing Maintenance Incident Report IR 92-023 and after interviews with the maintenance superintendent and the I&C:

supervisor, the inspectors noted a similar problem which occurred on September ~28, 199 During-performance of a survoillance test on PR NI channel "N 41", values listed in the test data shects were different from the required values given in the plant curve book. Upon further investigation, by FNP, it was determined that '

while the correct curve, curve r. umber "71B",'had been used, the

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wrong column of data, the data for NI channel "N-42", was used rather than data for "N-41". Corrective action for this event

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included procedural changes which required better verification of

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data usage and entry and " coaching" of the individual. Counselin emphasized importance of- an individual's recoonsibilities under *

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self-verification. The licensee has issuet init-E LER 92-012 to ,

document the circumstances and conditions ru ated to this even The above December 16th incident, involving NI channel "N-43" is identified as a non-cited violation (NCV) and will not be subject to enforcement action because of licensee's efforts in identifying and correcting the violation meet criteria specified in Section VII.B of the Enforcement Policy. This item is identified as NCV ,

50-364/92-35-02, wrong data used for NI PR channel "N43" potentiometer settin No other deviations or violations were identified in this area. The results of inspections in this area indicate that personnel conducted assigned activities in accordance with applicable procedure . Emergency Preparedness Exercise (82206)

On December 9, NRR personnel, the resident inspectors and Region II Emergency Preparedness section personnel observed a annual emergency preparedness and plant-wide accountability exercise. Specifics of.this exercise can be found in inspection report 50-348,364/92-33.--

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Within areas observed, no. violations or weaknesses were identifie . Evaluation of Licensee Self-Assessment Capability (40500)

Inspectors attended a meeting of the Plant Operations Review Committee (PORC) on December 16. The meeting was chaired by the General Manager, Nuclear Plant and a quorum was-present as required by Technical Spe ' C 2' ion 6. The up da included discussions of plant change notices (PCNs), minor:

departures including a drawing change for a Unit I refueling upender limit switch, various procedural changes and an LER for the Unit 1 loss of site power event in Novembe Members were prepared for the discussions, had knowledge.of the issues, -

and' discussion among the PORC-members was uninhibited and-_ encouraged by the chairman of.the committe The licensee's self-assessment program, 'specifically PORC activities, are adequate and no violations or deviations were-identifie . _ _

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- Action on Previous Inspection Findings (92702)

(Closed)UNR 50-348/92-24-03 and 50-364/92-24-01,- Failure to properly-control commercial-grade-lubricants resulting in use of non-conforming ;

lubricant in safety related equipmen Monthly resident inspection ra ' 50 348,364/92 24, paragraph 3b(2),

identified unresolved items co,w ag the use of Texaco " Regal R&O 68" oil rather than required " Regal h.0 32" oil in safety +related equipment. . .i

A special inspection was later conducted and results were documented in Region 11 inspection report 50-348,364/92-26. This special report t allowed these items to remain ope The site issued a corrective action report, (CAR-1982), documenting circumstances and condit'ons concerning mis-application of Texaco " Regal

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R&0 68" oil. The report shows that corrective actions to alleviate the adverse condition have been completed and that part of the actions to prevent recurrence have also been completed. However, a Notice of Violation (N0V) is being recommended because work activities have not, at the time of this report, been thoroughly reviewed to ensure no.-

"other" materials are being controlled in a manner which could allow for the inadvertent use of nonconforming " commercially purchased" material-in safety-related applications. While it is noted that site managers have been directed to conduct the above reviews, these reviews have not been completed and the estimated CAR completion date of March 1, 1993 has been projected, Subsequent review by NRR and Region 11 personnel, determir.., ' hat the above unresolved items should be closed and reidentified as s NO Refer to Region II Inspection reports 50-348,364/92-24 and 50-  :

348,364/92-26 for specifics / details about the proposed violatio The use of mislabeled oil safety-related equipment,is an example of a l

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failure to properly control nonconforming material.- Unresolved Items 50-348/92-24-03 and 50-364/92-24-01 are closed and are now identified as Violatico 50-348,364/92-35-01: Failure ta properly-and-adequately-contrci site lubrication oil resulting in use of-nonconforming lubricant-

in safety-related equipmen . Exit Interview i- The inspection scope and findings were summarized during management n interviews throughout the report period and on January 8, 1993, with the.

L plant manager and selected members- of his staff. The inspection findings-

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were discussed in detail. The licensee questioned why the NOV was not-E issued as an NCV. The licensee acknowledged the inspection findings and--

L did not identify as proprietary any material. reviewed 'by the inspectors -

during this inspectio 'The licensee was informed that items-discussed in paragraph 8, WR 50-348/92-24-03 and UNR 50-364/92-24-01, were closed. They were also informed that IFI 50-364/92-25-01- remains open.

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ITEM NUMBER DESCRIPTION AND REFERENCE 50-348,364/92-35-01 (NOV) Failure to control site lubrication oil resulting in use of non-conforming .

lubricant in safety-related equipmen /92-35-02 (NCV) Wrong data used for NI PR channel "N-43" potentiometer settin ..,

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1 Acronyms and Abbreviations Auxiliary Feedwater

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AFW -

ALARA - "As low As Reasonably Achievable" A0P -

Abnormal Operating Procedure AP -

Administrative Procedure APC0 - Alabama Power Company .

BTRS - Boron Thermal Regeneration System CFR -

Code of Federal' Regulations CVCS - Chemical and Volume Control System CCW -

Component Cooling Water CRDM -

Control Rod Drive Mechanism CS -

Containment Spray System DDFP -

Diesel Driven Fire Pump D/G -

Emergency Diesel Generator '

DRP -

Division of Reactor Projects DPM - Disintegration Per Minute ECP -

Emergency Contingency Procedure i EIP -

Emergency. Plant Implementing Procedure ENN -

Emergency Notification Network-E0F - Emergency Operations facility EP -

Emergency Preparedness =

EPA - Environmental Protection Agency EQ -

Environmental Qualifications ESF - Engineered Safety Features F -

Fahrenheit FNP -

Farley Nuclear Plant FSP- -

Fire Surveillance Procedure GPM -

. Gallons Per Minute HHSI -

High Head Safety Injection-HSB -

Hot Standb I&C -

Instrumentation and Controls '

IN -

Information Notice-ISI- -

Inservice Inspection-IST -

Inservice Test LCO -

Limiting Condition for Operation LHSI - Low Head Safety Injection LLRT - -Local Leak Rate Testing LER -

Licensee Event Report _

MDFP - Motor Driven Fire Pump M0V -

Motor-0perated Valve l

MOVATS- Motor-0perated Valve Actuation Testing MWR -

Maintenance Work Request l

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NCR - Nonconformance Report NI - Nuclear Instrumentation - -

NRC -' Nuclear Regulatory Commission NRR . - NRC Office of_ Nuclear Reactor Regulation NSSS -

Nuclear' Steam Supply _ System 0ATC - Operator at the_ Controls OSHA -

Occupational _ Safety and Health Administration OTDT - Over-temperature Differential Temperature-PAP- -

Primary Access-Point PCB -

Plant Curve Book PCCV - Positive Closing Check Valve PCN - Plant Change Notico PCR -

Plant Change Request PMD -

Plant Modifications Department PORV - Power Operated Relief Valve PPB -

Parts Per Billion PPM - Parts Per Million PR -

Power. Range PRT -

Pressurizer Relief Tank PSID -

Pressure per Square Inch Differential PVC -

Polyvinyl Chloride PZR -

Pressurizer RCP -

Reactor Coolant. Pump RCS -

Reactor Coolant System RHR -

Residual Heat Removal RPC -

Rotating Pancake Coil RTD -

Resistance-Temperature Detector RWST -

Refueling Water Storage Tank S/G -

Steam Generator .

SI -

Safety Injection SAER -

Safety Audit and~ Engineering Review SCS -

Southern Company Services SFI -

Shift Foreman - Inspecting SF0 -

Shift Foreman'-~0perating-SGFP -

Steam Generator Feedwater Pump-50 -

Systems Operator SFP -

Spent Fuel Pool-SNC -

Southern Nuclear Operating Company I Standard Operation Procedure

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S0P -

SP -- Systems Performance Grou SPDS - Safety Parameter Display System SS -

Shift Supervisor SSPS -

Solid State Protection System STAR - "Stop, Think,-Act,. Review"-

STP - Surveillance Test Procedure; SWS- -

Service Water:. System TS -

Technical Specification TSC -

Technical Support Center VCT -

V91ume Cont %I Tank VDC -

Voltage Direct Current WA -

Work Authorization h g