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Insp Repts 50-498/87-31 & 50-499/87-31 on 870505-29.No Violations or Deviations Noted.Major Areas Inspected: Licensee Action on Previous Insp Findings,Tmi Action Items Followup,Preoperational Test Witnessing & IE Bulletins
	ML20216H448
Person / Time
Site:	South Texas
Issue date:	06/24/1987
From:	Carpenter D, Constable G, Luehman J, Mullikin R, Greg Pick, Reis T, Staker T; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:	;
Shared Package
ML20216H415	List: ML20216H410; ML20216H448;
References
	TASK-1.A.2.3, TASK-1.A.3.1, TASK-2.K.3.09, TASK-TM 50-498-87-31, 50-499-87-31, IEB-79-06, IEB-79-6, IEC-77-05, IEC-77-5, IEC-81-03, IEC-81-14, IEC-81-3, NUDOCS 8707010407
	Download: ML20216H448 (11)
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' APPENDI'X-

>U. S. NUCLEAR REGULATORY COMMISSION

REGION IV

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NRC' Inspection ,Reporti ' . 50-498/87-31- Construction Permits: CPPR-128

' 1 % 50-499/87-31' CPPR-129'

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Dockets: 50-498' '

Expisation Date: -December 1987 and

50-499: December 1989

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" Licensee: Houston Lighting & Power Company (HL&P). _

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Houston,l Texas 77001 !

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FacilityLName: South Texas Project, Units 1 and 2-(STP) j

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Inspection At: STP, Matagorda County, Texas S

Inspection Conducted: May.5-29, 1987

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Inspector _s: -

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. R. Carpenter, Senior. Resident Inspector. . Date

Project Sectior. C, Reactor Projects Branch

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T. Reis, Resideht Inspector, Project Section C Date-

Reactor,PrqjectsBranch

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T. Staker, Resident Inspector, Project Section A

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< Reactor' Projects Branch

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J. G. Luehman, S6nior Resident Inspector

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$G. Pick,

h" Reactor Inspector, Operations Section

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Reactor Safety Branch .

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7' R. Mullikin, Project Inspector, Project Section B

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.R6 actor Projects. Branch'

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- Personnel:-- J. F. Lara, 00-OP Student'

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(Approved: ._

G...L. Constable, Chief, Project Section C

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Reactor Projects Branch

Inspection Summary

Inspection Conducted May 5-29,1987(Report 50-498/87-31; 50-499/87-31)

-Areas Inspected: Routine, unannounced inspection including licensee action on

previousinspectionfindings,ThreeMileIsland(TMI)actionitemsfollowup,

preoperational test witnessing, preoperational test results review,.

IE' Bulletins and Circulars, security, and site tours.

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

identified.

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DETAILS

1. Persons' Contacted

Principal Licensee Employees

W. H. Kinsey, Plant Manager

G. L~. Parkey,' Technical. Services Manager

1*W. G. Isereau~, Operations Quality Assurance Manager. 1

, *L. J. Ryley, Physical Protection Services Manager

A. 0. ' H111, Nuclear Security Manager

S. M. Head, Lead Engineer, Licensing j

E. L. Brown, Licensing Engineer'

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M.' A. McBurnett, Supervisory Licensing Engineer

W. Harrison, Supervisory Licensing Engineer

C, Turner, HL&P Engineering

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In addition to the above, the NRC inspector also-held discussions with -j

various licensee, AE, constructor, and other contractor personnel during ;

.this. inspection.

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Denotes those individuals attending one of the exit interviews conducted

on May 28 and 29, 1987.

2. Unr'esolved Items

An unresolved item is a matter about which more information is required to

ascertain whether it is an acceptable item, a deviation, or a violation.

An unresolved item is identified in paragraph 6 of this report.

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3. Licensee Action on Previous Inspection Finding .

(Closed)OpenItem 498/8605-01; 499/8605-01

This item identified inconsistencies between-Plant "

ProcedureOPGP03-ZE-0022,"InserviceTestingProgramsfor.

Revision 0, and the draft copy of the Technical SpecificationsPumps (TS).

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testing frequency for pumps as stated in the plant procedure deviated from l

the requirements of the TS. -The procedure has been revised to adequately

comply with the draft TS.. This item is considered closed.

(Closed) Open' Item 498/8605-02

This item consisted of the preoperational testing for the 125 VDC 1E

Battery System (1-DJ-P-04) during which four acceptance criteria !

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' requirements were.not met. The following nonconformance reports (NCR) '

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were initiated to identify and resolve the nonconforming test results.

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Report 86-05 Section NCR No.

8.a SE-03903

8.b SE-03905

8.c SE-03904

8.d SE-03910

The NRC inspector reviewed the 1-DJ-P-04 test results package which-

included engineering disposition of the above nonconforming items. The

NCR resolutions were independently reviewed by the NRC inspector to ensure

that they conformed with applicable Industry Standards IEEE 450-1975, IEEE 485-1978, NEMA PVS-1976, and Regulatory Guides 1.32 and 1.68. The closure

of the above NCRs adequately resolves the NRC inspector's concerns as to

the acceptability of the preoperational test results.

This item is considered closed.

(0 pen) Open Item 498/8717-01, Installation And Testing of the Emergency

Lighting Required For Safe Shutdown

The NRC inspector walked down the areas where emergency lighting is

required if a fire causes evacuation of the control room. These areas

were found to have adequate lighting. In addition, Preventive

Maintenance (PM) Procedure EM-1-LB-87013194, Revision 1, " Emergency DC

Lighting (Appendix R)," was in the approval stage which will require a

yearly illumination check of the lights. The post installation inservice

tests for.the lighting was not completed. This item will remain open

pending approval of the PM procedure and completion of acceptance tests.

(Closed) Open Item 498/8717-03, Installation of Additional Detectors For

Containment Water Curtain Actuation

The licensee committed to installing additional protecto-wire line-type

thermal fire detectors under some cable trays in containment. The NRC

inspector reviewed Field Change Request (FCR) HBE-02255 and the actual

installation, and found it acceptable. Also reviewed was Station

Procedure OPGP03-ZF-0012, " Fire Fighting," Revision 1, which gives the

response required to alarms generated by the additional detectors. This <

item is closed.

(0 pen) Open Item 498/8717-04, Relocation of Sprinklers, Installation of

Thresholds in Relay Room, and Completion of Halon Concentration Test in

Relay Room

The NRC inspector reviewed the completed FCR and visually inspected sample

areas and found no sprinkler heads less than 18 inches from the ceiling

except in the relay room where obstructions made it impractical. In

addition, the relay room thresholds were found to be installed. The Halon

test was completed but the results had not been accepted by the end of the

inspection. This item will remain open pending acceptance of the Halon

concentration test in the relay room.

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(Closed)OpenItem 498/8717-09,' Addition of Five Dampers in Fire Area 77

The NRC. inspector reviewed FCR SH-00245'for the installation of two fire

dampers in the heating, ventilating, and air conditioning (HVAC) ducts in

Fire Area 77. :This item is closed.

'(Closed)OpenItem 498/8717-10 Analysis of Effects of Open Secondary

Circuits on current Transformers

The NRC' inspector' reviewed the licensee's analysis and found it

acceptable. This' item is closed.

(Closed)OpenItem 498/8717-11, Analysis of Safe Shutdown Communications

The NRC inspecto'r reviewed the licensee's documentation that stated that

at least one method of communication will be unaffected by a fire that

requires the abandonment of the control room. This item is closed.

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(Closed) Open Item 498/8613-02, Preoperational Procedure Review Findings

This item concerned the use of ambiguous terms such'as " extent necessary"

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for criteria in certain preoperational procedures without offering

guidance as to what constitutes " extent necessary." The specific

procedures have been changed to delete such phases. The procedure changes

were reviewed by the NRC inspectors and deemed satisfactory. This item is

considered closed.

. (Closed)OpenItem 498/8613-01, Preoperational Procedure Review Findings

This~ item concerned using acceptance criteria in procedures without

guidance as to what is acceptable. The criteria in this instance was

found to be superfluous as such abnormalities are routinely watched for

and covered by Startup Administrative Instruction (SAI) 18,

paragraph 5.3.4. The procedure was changed and deemed satisfactory by the

NRC inspectors.

(Closed)OpenItem 498/8708-47

Field Change Notice (FCN)87-406 for Procedure OPMP04-CC-0001, Revision 3,

" Component Cooling Water Pump Maintenance," was issued to correct the

sequence of Steps 5.12.5 and 5.12.4 on the data sheet and to correct the

required torque valves of the motor mounting bolts. This item is closed.

(Closed)OpenItem 498/8708-48

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FCN 87-416 to OPMPO4-FC-0001, Revision 1, " Spent Fuel Pit Cooling Pump

Maintenance," added a " Documentation" section, a note referencing the

addendum and corrected the data sheet step numbers to agree with their

respective procedure step numbers. The reference to total indicated ,

runout was identified on the data sheet. This open item is closed.

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(Closed)OpenItem 498/8708-49

FCN 87-410 to Procedure.0PMP04-JF-0001, Revision 0, " Fuel Handling Machine

Inspections," added the necessary note and properly renumbered the -

procedure' steps. This open item is closed.

(Closed) Open Item 498/8708-53

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FCN 87-407 to Procedure OPMPO4-DG-0004, Revision 0, " Standby Diesel l

Generator Starting Air Compressor Maintenance," added a " Documentation" i

section and corrected what the columns required for data on the data sheet ,

in Steps 5.13.4 and 5.13.7. This open item is closed. l

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(Closed) Open Item 498/8708-57

FCN 87-423 to Procedure OPMP04-SI-0002, Revision 1, "High Head Safety

Injection Pump Maintenance," corrected / reverified the torque valves in the

steps identified and corrected the acceptance criteria for the " head and

bowl bearing running clearance" to agree with the specified valves in the

vendor manual. The FCN added a step on the data sheet for the torqued

valve of the fourth through seventeenth stage bowl fasteners and added a

torque wrench for torquing smaller sized fasteners. This open item is

closed.

(Closed) Open Item 498/8708-54

Maintenance Procedure OPMP04-DG-0005, Revision 0, " Standby Diesel

Generator Engine Maintenance," was cancelled with Plant Operations Review

Committee (PORC) approval in May 1987. The work will be accomplished by

Preventative Maintenance Procedure OPMP04-DG-0003, " Standby Diesel

Generator Inspection," and any corrective maintenance will be handled with

detailed work instructions through a maintenance work request (MWR). This

open item is closed.

(Closed) Open Item 498/8708-55

Maintenance Procedure OPMP04-ZG-0017, Revision 0, " Pacific Gate Valve

Maintenance (Bolted Bonnet)," was cancelled with PORC approval in May

1987. The work will be accomplished utilizing General Valve Maintenance

Procedure OPMP04-ZG-0103. This open item is closed.

The following procedure observations, as stated by the NRC inspector in

NRC Inspection Report 50-498/87-08, were addressed by the use of procedure

FCNs. The procedure affected and its corresponding FCN are listed below:

Procedure FCN

OPMP04-AF-0001 87-402 j

OPMP04-FW-0003 87-403

OPMP04-RC-0007 87-409

OPMP04-ZG-0006 87-408

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4 Three Mile Island (TMI) Action Items Followup

(Closed) TMI Item I.A.2.3, Administration of Training Programs

The NRC inspector reviewed STP Interdepartmental Procedures IP 8.8,

Revision 1, " Licensed Operator Training Program," and IP 8.9, Revision 0,

" Licensed Operator Requalification," and determined that the procedures

required'through training and requalification that facility instructors

who taught systems, integrated responses, and transient responses were SR0

qualified or NRC Certified Instructor personnel. This item is considered

closed.

.(Closed) TMI Item I. A.3.1.3, Revise Scope and Criteria for Licensing

Examination - Simulator Exams

The NRC inspector determined through discussions with training personnel :

that a plant specific simulator should be operational in November 1987. ,

Simulator training was required by IP 8.8, Revision 1, " Licensed Operator

Training Program," with requalification simulator training required by

.IP 8.9, Revision 0, " Licensed Operator Requalification." This item is

considered closed.

(Closed) TMI Item II.K.3.9, Proportional Integral Derivative Controller

Modification

The NRC inspector verified through review that FCR SZ-00290 removed the

jumpers necessary to ensure that the derivative action of Pressure

Controller PC-655A for the pressurizer power operated relief valve was

disconnected. This item is considered closed.

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5. Preoperational Test Witnessing

During the period the NRC inspector witnessed various portions of diesel

generator preoperational testing. The tests were executed properly with

approved procedures and the results obtained meet the requirements of

Regulatory Guide 1.108. However, two hardware problems that occurred

during testing require substantiation to prove diesel reliability. One

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item concerns the failure of a high pressure fuel injector over the !

weekend of May 23-24, 1987. It was reported the morning of May 26 that an i

injector physically blew off its cylinder during a 24-hour reliability

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run. The test was aborted, the injector replaced, and the test

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reperformed satisfactorily. The root cause of the injector failure was

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not reported to the NRC. On the evening of May 28, 1987, at the end of a

repetitive start reliability test on Emergency Diesel Generator (EDG) {

No. 12, a high pressure fuel pump broke free from the engine. The

component was replaced and the engine underwent further repetitive start

testing before being considered acceptable. The NRC inspector noted that

the recent testing was a reperformance of the original required

preoperational tests. The original tests were reperformed because diesel

reliability was at that time questioned due to similar mechanical

failures. In view of the two recent failures and the past history of

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diesel failures, a technical evaluation will be necessary to justify

confidence in the reliability of the diesel generators. Diesel generator

reliability is considered an open item (498/8731-01) pending licensee

response.

6. .Preoperational Test Results Review

The NRC. inspector continued the review of results.for selected completed

preoperational' tests. Additionally, a cross check was performed between

the preoperational test requirements of the STP Final Safety Analysis

Report (FSAR) Paragraph 14.2.12.2, Regulatory Guide 1.68, and the existing

preoperational test procedures.

The reviews of the completed preoperational test procedures were done to

verify that the testing of systems met specified acceptance criteria,

problems encountered during testing were properly resolved, appropriate

reviews of the test results were performed, and that approved l

administrative controls were followed during the conduct of testing. The i

completed tests reviewed included:

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1-SI-P-03-00, Safety Injection System Check Valve Testing

1-MS-P-01-00,MainSteamHotFunctionalTest(HFT)

1-RS-A-01-00, Control Rod Drive Mechanism (CRDM) Power Supply

(MotorDrivenGeneratorSets)

1-RS-P-02-00, CRDM Operation

1-RM-P-04-01, Residual Heat Remover (RHR) Thermal Performance

1-RC-P-02-01, Reactor Coolant System (RCS) HFT

1-AF-P-01-02, Auxiliary Feedwater System ( AFWS)

1-AF-P-02-01,AFWS(TurbineDrivenPump)

1-AF-P-03-00, AFWS Water Hammer Test

1-CV-P-01-01, Chemical and Volume Control System (CVCS) Charging,

Letdown and Seal Injection

1-SP-P-01-01, Reactor Protection Logic

1-HC-P-01-01, Reactor Containment Building (RCB)

HVAC(Safety-Related)

The review of the acceptance /preoperational tests list in FSAR ,

paragraph 14.2.12.2 revealed that there were no approved tests for either

the 345 KV switchyard or the Boron Concentration Measurement

System (BCMS). The lack of an acceptance test for the BCMS, though

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contrary to the FSAR,.is not considered significant as this. system neither

performs.or supports any. safety function. _ Additionally, the system will

be calibrated and functionally tested prior to use , The lack of a test

_. for the:345.KV switchyard is considered more significant=especially .!

. because the licensee is pursuing the deletion of the loss-of-off-site'

power test from the startupitest program. The inclusion of-an acceptance

test for the 345.KV switchyard is considered an unresolved item

(498/8731-02)-pending discussions'with the NRC Office of-Nuclear Reactor

-Regulation (NRR), and licensee followup of exactly what, if any,

acceptance. testing has been done on the system by the licensee's

. non-nuclear organization.

~7. IE Bulletins (IEB) and IE Circulars.(IEC).

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.(Closed) IEC 77-05 Liquid Entrapment in Valve Bonnets

This circular addresses gate valves which have in'some instances failed to

open due to disc binding. .This binding is usually due to. thermal

contraction or high pressure.' water. trapped in the bonnet cavity which is. a

known.as pressure locking. Six double disc valves were identified at STP '!

as-having..the potential for pressure 1.ocking. Thermal c'ontraction has

been. determined to not apply to STP due to the valve application.~ The six

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identified valves were tested several times during HFT to determine the ,

-a bility of these valves to;open under pressure locking conditions. There '

. was no difficulty experienced in opening any of the identified valves.

This circular is considered closed.

(Clo' sed)'IEC 81-03 Inoperable Seismic Monitoring Instrumentation

This' circular describes the failure of seismic instrumentation due to

. inadequate maintenance.' The following procedures address the IEC's

maintenance recommendations:

~ ~1 PSP 02-SY-0001 " Triaxial Time History ACOT"

1 PSP 02-SY-0010 "Self Contained Triaxial Time History ACOT

(X-0010)"

1 PSP 05-SY-0010 "RCB Foundation Self Contained Seismic ~ Channel

Calibration (X-0010)"

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The following procedures will be approved prior to the first refueling '

outage to comply with the TS 18-month calibration interval requirements.

1 PSP 05-SY-0007 " Reactor Vessel Remote Seismic Channel

Calibration" ,

"RCS Cold Leg Remote Seismic Channel Channel

1 PSP 05-SY-0008

Calibration"

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1 PSP 05-SY-0009 " Spent Fuel Pool HX. Remote Seismic Channel

Calibration"

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This' circular is considered closed.

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(Closed)'IEC 81-14,' Main Steam Isolation Valve (MSIV) Failures to Close !

This circular concerned the failure'of MSIVs to close due to poor quality 3

operating air or air systems and/or valve stem and packing binding. The. i

STP MSIVs are designed to close upon a loss of instrument air. . As part of

normal surveillance MSIVs are partially stroked at full power and fully

stroked in Modes 5 and 6 per plant Procedures IPSP03-MS-0001 and

IPSP03-MS-0002, respectively. This circular is considered closed.

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(Closed) IEB 79-06, Review of Operational Errors and System Misalignments

Identified During The Three Mile Island Incident

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This bulletin is obsolete. It is superseded by IEB 79-06A discussed ;

below.

(Closed) IEB 79-06A, Review of Operational Errors and System Misalignments

Identified During The Three Mile Island Incident

The majority of the items identified in this bulletin have been

incorporated into the TMI Action Items (NUREG-0737) program reviewed.in

-NRC' Inspection Reports 50-498/87-08 and 50-498/87-23. The remainder have

been incorporated into the licensees operational procedures program to the

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satisfaction of the NRC inspector. This bulletin is considered closed.

8. Secu'rity

The NRCLresident inspectors observed the implementation of the final

security plan the. week of May 23-29 and considered the implementation

relatively smooth and effective. The NRC inspector acknowledges that this

is a " phase-in" to full lockdown and that full lockdown of the protected

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area is not' required at this time. However, the inspector notes a

significant amount of tailgating of Nuclear Plant Operations

Department (NP00); personnel through various mechanical electrical

auxiliary building (MEAB) key card doors.

Additionally, the NRC . inspector observed that a surveillance of all power

block ~ locked doors is warranted. Surveillance and repair of .

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malfunctioning doors will be tracked as an open item (498/8731-03). !

9. Site Tours

The NRC inspector conducted site tours both independently and accompanied ,

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by licensee personnel. These tours were made primarily to assess the

condition of 1.nplace safety-related equipment, plant status, and to

observe ongoing preoperational testing and work activities. The areas

toured included:

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' Uni t '17-- MEAB, RCB, fuel handling building (FHB),; emergency diesel ~!

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' generator; building;(EDGB),~andtheisolationLvalve: cubicle-(IVC).

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Unit 2 - MEAB, RCB, FHB,'EDGB,'and IVC.-

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21 0 .- Exit Interview

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The.NRCinspector'metwith-llicenseerepresentatives(denotedin

paragraph ~1) on May 28 and 29;'1987,L and. summarized' the scope:and findings -

ofzthe inspection.

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ML20216H448

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