ML20154S461

Insp Repts 50-498/88-25 & 50-499/88-25 on 880411-15.No Violations or Deviations Noted.Major Areas Inspected:Unit 1 Control Room Activities

ML20154S461
Person / Time
Site:	South Texas
Issue date:	05/18/1988
From:	Hildebrand E, Ireland R, Andrea Johnson NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20154S380	List: ML20154S376 ML20154S461
References
50-498-88-25, 50-499-88-25, NUDOCS 8806090072
Download: ML20154S461 (9)

See also: IR 05000498/1988025

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APPENDIX

U.S. NUCLEAR REGULATORY COMMISSION (

REGION IV

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NRC Inspection Report: 50-498/88-25 Operating License: NPF-76

50-499/88-25 Construction Pennit: CPPR-129  ;

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Dockets: 50-498 ,

50-499

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Licensee: ' Houston Lighting & Power Company (HL&P) i

P.O. Box 1700

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Houston, Texas 77001 .

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Facility Name: South Texas Project (STP), Units 1 and 2  !

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j Inspection At: STP, Matagorda County, Texas  !

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Inspection Conducted: April 11-15,1988  ;

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Inspectors: 8 90 ov>8 bl 3,/96  ;

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A. R. Johnson, Reactor Inspector, Plant Date

Sys tipi, Division of Reactor Safety

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A E. P. Hildebrarid, Reactor Inspector, Plant ~,

p Systems Section, Division 1f Reactor Safety

Approved: .G f/I, M s//r//j'[

R. E. Ireland, Acting CMef, Plant Systems Date / [

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Section, Division of Ractor Safety '

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Inspection Summary  ;

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l Inspection Conducted April 11-15, 1988 (Report 50-498/88-25)  !

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Areas Inspected: Routine, announced inspection of Unit I control room ,

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Results: Within the areas inspected, no violations or deviations were

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8906090072 830527 .

PDR ADOCK 05009498  !

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Inspection Conducted April 11-15,M988 (Report 50-499/88-25)

Areas Inspected: Routine, announced inspection of Unit 2 standby diesel

generator maintenance, electrical systems, component startup testing records,

and HL&P's response to NRC Bulletin 88-01 regarding defects in Westinghouse

DS 416 and DS 206 series circuit breakers.

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Results: Within these areas, no violations or deviations were it. led.

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DETAILS ,

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1. Persons Contacted

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• J. T. Westermeier, Project Manager ,

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, *G. L. Parkey, Plant Superintendent, Unit 2 ,

• J. S. Phelps, Supervising Engineer, Project Compi,iance

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K. O'Gera,- Froject Compliance

s. - *S. D. Phillips, Project Compliance -l

1 *G. Ondriska, Ftartup Engineering

J. A. Slabinski, Unit 2, Operations Quality Control (QC) Supervisor ,

H. Murray, Unit 2 Operations QC  :

P. Bufkin, Unit 2 Operations QC

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J. Curran, Unit 2 Operations ~

D. Nester, Unit 2 Operations i

R. A. Hernandez, Project Quality Assurance (QA)

J. J. Johnson, Project QA '

• M. Duke, Engineering

, *W. ,Trujillo, Supervisor, Nuclear Assurance

r *M( 2. Powell, Supervising Engineer, Licensing ,

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B., Evans, Licensing Engineer .

Bechtel

• R. W. Miller, Project QA Manager

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• R. H. Medina, QA Supervisor

A. Carpenter, Startup Engineering

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s D. R. Carpeiker, Senior Resident inspector -

• G. L.L Constable, Chief, Division of Reactor Projects, l

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Project Section D

• A. R. Johnson, Division of Reactor Safe,ty (DRS), Region TV (RIV)

• E. P. Hildebrand, DRS, RIV ,' ',

• Denotes those present at the exit interview.

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2. 'hectrical Systems and Components, Unitj ,

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The NRC inspector selectively sampled and evaluated safety-related quality

records pertaining to electrical systems and components regarding: medium

voltage air circuit breakers (4.16KV and 480V), prouctive and auxiliary

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relays, current / potential transformers, meters and transducers, insulation

resistance (megger) testing, ahd scheme and plant wiring verification.

The inspection included record review to detennine whether: the licensee

was preparing, reviewing, and maintaining records properly; records

reflected work accomplishment consistent with NRC requirrnents and FSAR

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coninitments; and: records indicated any potent 911y generic problems,

management control inadequacies,'ar other weaknesses.

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a. Startup Testing Records

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(1)/ prowdures to evaluate the above electrical systems andThcNRC

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Procedure i

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,/ SG-E-06, Revision 41 J, Medium i'pitage Air Circuit Breakers

SG-E-16,Revis18(f3' , Current / Potential Transformers

SG-E-23, 9efision Y '

Meters and Transducers

t i SG-E-29 % vision 4 'Protecth e and Auxiliary Relays

I Scheme' Verification

SG-E-03, Revision 8 q;

SG-E-13, Revision 7 Insulatihn Resistance (Megger) Testing

Also,theNRCinspectorrdiswedthefollowingvendor

installation, operation, ind inaintenance instruction manuals

for: guideline adjustrrente, settings, tolerances, and startup

testing requirements recommended by the manufacturer.

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Y' Instruction Manual / Bulletin Description ,

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,$ IB-18.1.7-2, Issue H ITE Brown Boveri Ground Protection

fr/I ) Fault Relays

1B-7.2.1.7-1, Issue A ITE Brown Boveri Overcurrent

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Relays

IB-8.2.7-2, Issue K - ITE Gould-Brow'1 Boveri SKV i

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Type 5HK Power Circuit Breakers

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I.L.41-759.4A, March 1979 Westinghouse Type AR High Speed

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Auxiliary' Relays

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198 4555K10-u01E, General Electric Type AB Anrneters

Revision 8-74 ',

s pnd Voltmeters

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GEH-230AE, Revisien,1-77 General Electric 600V thru 15KV

,j Instrument Transformers

(2) The NRC inspector reviewed and evaluated the HL&P startup

testing data and records associated with the electrical systems

and components identified in Table 1 (attached).

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The NRC inspector also reviewed and evaluated the startup

i testing data and records associated with the scheme verification

I and insulation resistance (megger) testing of the 'ollowing

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?)j TSystem (Description) System ID (Test No.)

4.16KV SG E1C Cub 12 Fdr to 480V ESF LC E1C C2PK02C3SC

(Scheme Verification) .(2PL01-141297 & P01)

4.16KV SG E1C Cub 13 Fdr to 480V ESF LC E1C C2PK03C3SC

(Scheme Verification) (2PL01-141299 & P01)

4.1$KVSGE1CCub12Fdrto480VESFLCE1C C2PLACC1GA

(MeggerTesting) (2PL01-162637)

/ i.16KV SG E1C Cub 12 Fdr to 480V ESF LC E1C C2PLACC1GA

(MeggerTesting) (2PL01-162638)

Mo violations, deviations, or unresolved items were identified.

3; p,efectsinWestinghouseDS416andDS206SeriesCircuitBreakers

/ . NRC Bulletin No. 88-01 provided information on Westinghouse series DS

\' ' circuit breakers (CBs) and safety concerns associated with their use. The

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Bulletin required licensees using these breakers in Class 1E service to

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, perform and document: inspection of the welds on pole shafts, and

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inspection of the alignment in the breaker closing mechanisms. HL&P

evaluated the Bulletin and submitted a response to the NRC dated March 29,

1988. South Texas Project (STP), Units 1 and 2 use DS series CBs in

Class 1E 480V load center applications, supply CDs, feeder CBs, motor

generator set output CBs, reactor trip CBs, and reactor trip bypass CBs.

STP, Units 1 and 2 have a total of 104 series DS CBs (52 in Unit 1 and 52

in Unit.2) in Class 1E applications. Six are in the reactor trip

switchgear for each unit, and 46 are in 480 Vac load center applications

for each unit.

HL&P performed inspections in accordance with Westinghouse Technical

Bulletin No. NSID-TB-87-11 on reactor trip, trip bypass, and motor

generator set output CBs of Unit 1, including replacements from Unit 2.

The results of these inspections indicated that: all CB mechanism

alignment inspections were satisfactory; all "short-term" inspections of

pole shaft welds were satisfactory (based on reduced inspection criteria,

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but with imposition of subsequent inspections at 200-cycle intervals up to

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' 4000 cycles, per Section 6.1.2 of the Bulletin); and "Long-term"

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inspections of a number of Unit 1 pole shaft welds were unsatisfactory

(based on welds that were less than 120 of 1/8-inch fillet, lack of

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fusion on welds for the auxiliary switch drive link, and porosity of welds

cc ' < of the anti-pumping and right stop levers). These pole shafts were

t1J replaced from those in Unit 2 CBs. All inspection results of the linit I

h pole shaft replacements from Unit 2 were satisfactory.

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HL&P is in the process of performing inspections of the remainder of the

DS series CBs utilized in Units 1 and 2. HL&P is inspecting these 480 Vac

Class 1E CBs to the following guidelines:

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Unit 1

Station Procedure OPMP05-NA-0008, Revision 3, has been revised to

incorporate the short-term and long-term inspection criteria of

Westinghouse Technical Bulletin NISD-TB-87-11. .This procedure is

being used by HL&P on a CB-by-CB basis for each of the remaining

Westinghouse DS series CBs. These inspections are being performed by

the HL&P operations group in conjunction with the HL&P CB preventive

maintenance schedule, pursuant to Bulletin 88-01.

Unit 2

As required by Bulletin 88-01, the remaining Class 1E Westinghouse DS

series CBs are being inspected in accordance with Station Procedure

No. OPMP05-NA-0008, and the results will be documented prior to fuel

loading. It should be noted that HL&P is using the reduced

inspection guidelines of Bulletin 88-01 on inspection of the three

primary welds (short-term inspections). As short-term inspections

are passed, repeated inspections at-200 cycle intervals up to a

maximum of 4000 cycles are required. A letter confirming completion

of the required short-term and long-term inspections by HL&P, with

documented inspection results, will be submitted to NRC in accordance

with the reporting requirements of Bulletin 88-01.

HL&P is preparing Station Procedure No. OPMP05-RS-0003 (draf t) which is

dedicated specifically to the instructions and guidelines for maintaining

Westinghouse type OS 416 reactor trip switchgear CBs. This procedure

considers the inspection and maintenance attributes of the Westinghouse

Owners Group Maintenance Manual (WOG) entitled "Maintenance Program

Manual MPM-W0GRTSDS416-01 for Westinghouse Type DS 416 Reactor Trip

Circuit Breakers and Associated Switchgear, Revision 0, dated November 30,

1986." Sertion 6, entitled "Inspection and Test Checklist," is designed

to identify the required mechanical and electrical inspection and

maintenance attributes to maintain Westinghouse type DS 416 reactor trip

CBs and their associated switchgear in a continuous state of operational

readiness. The checklist provides the maintenance techniques to ensure

that CBs protective trip, opening, and interlocks function properly. It

includes electrical performance checks, tests, tolerance measurements, and

the record requirements, including undervoltage trip attachment (UVTA) and

shunt trip attachment (STA) operation, needed to detect and correct a

degraded condition.

Station Procedure OPMP05-RS-0003 will replace OPMP05-NA-0008, Revision 3

(now in place), for type DS 416 reactor trip switchgear CBs only.

Station Procedure No. OPMP05-NA-0008 now provides instructions and

guidelines for maintaining Westinghouse type DS and DSL low-voltage power

circuit breakers (480 volt breaker tests). This procedure has considered

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the requirements of the Westinghouse vendor manuals, with recomendations

for. maintaining these CBs. However, all attributes of the WOG are not

necessarily included in Procedure OPMP05-NA-0008, Revision 3.

No violations or deviations were identified.

4. Unit 2 Standby Diesel Generator (SDG) Engine Maintenance

During this inspection period, work was in progress on the "A" train

diesel engine to replace the cylinder liner expansion seals. The

expansion seals had been subjected to microbiologically induced

corrosion (MIC) which caused some failures to occur. The expansion seal

failures are discussed in NRC Inspection Report 50-498/88-21 and

50-499/88-21.

The mechanics performing the work observed by the NRC inspector were from

Cooper-Bessemer Corporation. Some assistance was provided by EBASCO

construction. personnel. The work was being performed under a startup work

request (SWR) using Cooper-Bessemer procedures. QC for the work was

provided by a. contract-QC engineer. HL&P QC was also monitoring the work.

Torque wrenches used on the job were calibrated by the STP onsite

metrology lab for use with various adaptors and tool configurations. Work

practices observed included use of lockboxes for tools and parts storage,

bagging and tagging engine parts during disassembly, and housekeeping.

It was noted that the SDG "A" air motor jacking gear sump was icw on oil,

and gear wear was evident on the pinion gear. The Cooper-Bessemer lead

mechanic was informed, and he stated that he would notify the startup

engineering organization. This gear is used only for jacking the engine

during maintenance and does not affect engine operation.

In summary, the work effort on SDG "A" appeared to be well organized and

professionally conducted in accordance with the applicable site

procedures.

No violations or deviations were identified.

5. Unit 1 Operation - Control Room Observations

During this inspection period, Unit 1 operations activities were observed.

The reactor was at approximately 20 percent power and preparaticns were

being made to place a main feed pump in operation. The main feed pumps

were out of service because of alignment and vibration problems.

The conduct of operations personnel was formal and professional. Control

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Room logs were well maintained and thorough.

l Surveillance testing and maintenance was in progress, requiring personnel

to enter the control room frequently. Control room access was generally

l well controlled by the unit supervisor, but sometimes personnel would

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enter from the side entrance behind the electrical plant control boards

without obtaining permission. This resulted in the control room space

becoming crowded to the extent that excess personnel had to be asked to

leave by.the shift operations staff. This observation was discussed with

the shift supervisor.

During this observation period, the NRC inspector noted that permission

was requested to troubleshoot the steam dump control system. MWR-MS-55308

was the controlling. work document. The troubleshooting required jumper (s)

to be installed which would render the steam dumps inoperable. Permission

was granted to proceed with the work.

Subsequently, during the troubleshooting, the reference temperature (Tref)

signal failed. The Tref value is a function of turbine impulse pressure

and is used in the steam dump control system and rod control system.

Control room personnel were not aware that Tref would be unavailable

during the troubleshooting nor was the technician controlling the work.

The Tref signal was imediately restored and the technician stopped work

to discuss the occurrence with his foreman.

6. Exit Interview

An exit interview was conducted with HL&P personnel on April 15, 1988, at

i the conclusion of the inspection, during which the inspection findings

j were summarized. The information discussed at the exit was not

identified as proprietary.

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TABLE l'

' Component (Description) Component ID (Test No.)

ITE Gould Medium Voltage Circuit Breaker C2PKSG0E1C-12-CB

(4.16KV SG E1C Cub 12 Main Bkr to Xfmr E1C1) (2PL01-141290)-

ITE Gould Medium Voltage Circuit Breaker C2PKSG0E1C-13-CB

(4.16KV SG E1C Cub 13 Main Bkr to Xfmr E1C2) (2PL01-141291)

GE, AB-40 Ammeter C2PKSG0E10-12-A

(4.16KV SG E1C Cub 12 Fdr to 480V ESF LC E1C1) (2PL01-141303)

GE, AB-40 Ammeter C2PKSG0E1C-13-A

(4.16KV SG E1C Cub 13 Fdr to 480V ESF LC E1C2) (2PL01-141305)

Gould Current Transformer, 400:5, SKV C2PK5G0E1C-13-CT-ABC-50/51

'(4.16KV SG E1C Cub 13 CT ABC 50/51 to Xfmr E102) (2PL01-141301)

Gould Current Transformer, 400:5, 5KV C2PKSG0E1C-12-CT-ABC-50/51

(4.16KV SG E1C Cub 12 ABC CT 50/51 Relay) (2PL01-141300)

Gould Current Transformer, 1200:5, SKV C2PKSG0E1C-12-CT-ABC-SP

(4.16KV SG E1C Cub 12 CT ABC to Xfmr E101) (2PL01-141292)

Gould Current Transformer, 1200:5, SKV C2PKSG0E1C-13-CT-ABC-SP

(4.16KV SG E1C Cub 13 CT ABC to Xfmr E1C2) (2PL01-141294)

Gould Brown Boveri GR-5 Protective Relay C2PKSG0E1C-12-50G

(4.'16KV SG E1C Cub 12 Gnd Relay 480V ESF LC E1C1).(2PL01-141296)

~Gould Brown Boveri GR-5, Protective Relay C2PKSG0E1C-13-50G

(4.16KV SG E1C Cub 13 Gnd Relay 480V ESF LC E1C2) (2PL01-141298)

Westinghouse AR, Protective Relay C2PKSG0E1C-13-50GX

(4.16KV SG E1C-13 Aux Relay 50GX) (2PL01-141411)

Westinghouse AR, Protective Relay C2PKSG0E1C-12-50GX

(4.16KV SG E1C-12 Aux Relay 50GX) (2PL01-141410)

ITE Brown Boveri, SIL, Protective Relay C2PKSG0E1C-13-50/51

(4.16KV SG E1C Cub 13 50/51 to LCE1C) (2PL01-141304)

ITE Brown Boveri, SIL, Protective Relay C2PKSG0E1C-50/51

(4.16KV SG E1C Cub 12 Fdr to 480V ESF LC E1C) (2PL01-141302)