ML20235U944
| ML20235U944 | |
| Person / Time | |
|---|---|
| Site: | Farley  |
| Issue date: | 10/01/1987 |
| From: | Bradford W, Dance H, Miller W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20235U918 | List: |
| References | |
| 50-348-87-23, 50-364-87-23, NUDOCS 8710140327 | |
| Download: ML20235U944 (10) | |
See also: IR 05000348/1987023
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UNITED STATES
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NUCLEAR REGULATORY COMMISSION
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REGION 11
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101 MARIETTA STREET, N.W.
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ATLANT A, G EORGl A 30323
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Report Nos.: 50-348/87-23 and 50-364/87-23
Licensee:
Alabama Power. Company
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600 North 18th Street
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Birmingham, AL 35291
Docket Nos.:
50-348 and 50-364
License Nos.:
Facility name: Farley 1 and 2
Inspection Conducted: August 18 - September 10, 1987
Inspection at Farley site near Dothan, Alabama
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Inspec ors:
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W'. H. B r d f o rd
Date Signed
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W.'
MilUer, Jr.
Date si ned
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Approved by:
H. C. Dance, Section Chief
Dat'e Signed
Division of Reactor Projects
SUMMARY
Scope:
This routine, onsite inspection involved a review of:
surveillance
observation, monthly maintenance observation, operational safety verification,
radiological protection program, physical security program, engineered safety
systems inspection, and Enforcement Conference of the vendor interface
inspection.
Results:
One violation was identified, Failure to Properly Calibrate Starting
Air Receiver Pressure Switches for Emergency Diesel Generator Nos. 1-2A, 18 and
28 (paragraph 5.a.(1)).
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REPORT DETAILS
1.
Licensee Employees. Contacted:
J. D. Woodard, General Plant Manager
D. N. Morey, Assistant General Plant Manager
W. D. Shipman, Assistant General Plant Manager
R. D. Hill, 0perations Manager
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C. D. Nesbitt, Technical Manager
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R. G. Berryhill, Systems Performance and Planning Manager
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L. A. Ward, Maintenance Manager
L. W. Enfinger, Administrative Manager
B. Moore, Operations Supervisor
J. E. Odom,. Operations Unit Supervisor
B. W. Vanlandingham, Operations Unit Supervisor
T. H. Esteve, Planning Supervisor
J. B. Hudspeth, Document Control Supervisor
L. K. Jones, Material Supervisor
R. H. Marlow, Technical Supervisor
L. M. Stinson, Plant Modification Manager
J. K. Osterholtz, Supervisor, Safety A:Idit Engineering Review
Other licensee employees contacted included technicians, operations
personnel, maintenance and I&C personnel, security force members, and
office personnel.
2.
Exit Interview
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The inspection scope and findings were summarized during management
interviews throughout the report period and on September 11, 1987, with
the general plant manager and selected members of his staff.
The
inspection findings were discussed in detail.
The licensee acknowledged
the inspection . findings identified in paragraphs 5.a(1) and 5.a(3).
The
licensee did not identify as proprietary any material reviewed by the
inspector during this inspection.
An Enforcement Conference summary
related to the vendor interface inspection is in paragraph 9.
3.
Licensee Action on Previous Enforcement Matters (92702)
This item was not inspected.
4.
Unresolved Item *
See paragraph 5.a.(3).
"An unresolved item is a matter about which more information is required to
determine whether it is acceptable or may involve a violation or deviation.
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' Operational . Safety Verification
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l Plant Operations Review (71707)
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The inspectors observed. control room operations, reviewed applicable
logs and conducted discussions with control room operators during .the
- report period. ' Also, the operability of selected emergency systems
was verified, tagout records reviewed.and proper return to service of
-affected components was ver.ified. _ Tours of the auxiliary building,
diesel building, turbine building and service' water structure were
conducted ~.to observe plant equipment conditions, including fluid
, leaks and excessive vibrations and general . housekeeping efforts. The
verifications were accomplished by direct observation of monitoring
instrumentation, valve' positions, switch positions, accessible
hydraulic ~ snubbers, and review of completed logs, records, and
chemistry results.
The licensee's compliance with LC0 action
statements were reviewed-as events occurred.
The inspectors routinely attended meetings with certain licensee
management .. and observed various shift turnovers between shift
supervisor, shift foremen and licensed operators. These meetings and
discussions provided a daily status _of' plant operations', maintenance,
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and testing activities in progress, as well as discussions of
significant problems.
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The events reviewed during this reporting period included the
following:
(1)
Status Lights for Emergency Diesel Generator Starting Air
Receivers-
During routine inspections of the control room status and
annunciator boards, the inspectors noted that the status lights
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which indicate that normal air pressure is available in the air
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receivers to start the emergency diesel driven generators were
frequently not illuminated.
Upon further investigation it was
discovered that the pressure instrumentation was not set :in
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accordance with
tha plant design documents, Unit 1
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Instrumentation Set Point Index A-170750, and Unit 2 Set Point
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Index 205968.
The documents required the set points for the
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pressure switch on each receiver to diesel generator Nos.1-2A,
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1B and 2B to be set at 420 psig and to remain locked in the
alarm position until the pressure is reduced to less than 370
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psig.
The set points for diesel generator Nos. 1C and 2C were
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required to be set at 240 psig and to remain locked in position
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until the pressure is reduced to less than 210 psig.
However,
the most recent calibrations of the instruments for diesel
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generator Nos.1-2A,1B and 2B were set to close at 420 psig +Ig
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psig and to open at various points ranging from 406 to 422 ps
in lieu of the required 420 and 370 psig set points.
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instrument set points for generators IC and 2C were correct.
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The failure to properly calibrate the starting air ~ receiver
pressure switches ' for emergency diesel generator Nos.'l-2A,1B
and 2B is identified as Violation 348,364/87-23-1.
Subsequently, ,the licensee recalibrates' the pressure switches
for the. starting air receivers and the starting switches for the
air compressor. to' each receiver such that the starting air
receiver normal' air pressure indicator light will be energized
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when the pressure within each receiver is in the. normal' air
start range. These set points are as follows:-
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Set Points in PSIG
Set Points in PSIG
Emergency' Diesels'
Air Com)ressor
Status Light
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ON
OF;
ON
OFF
1/2 A, 1B, & 2B
375 475 '
470 37U-
1C & 2C
225 250
245 220
This action should assure that the status lights will be
illuminated when the air pressure in the air receivers is in the
normal acceptable range.
(2) Loss of Uninterruptible Power _ System for Unit 2 Turbine Driven
Auxiliary Feedwater Pump
On August 29, 1987, at 11:45 a.m. while Unit 2 was operating at
100% power a loss of power alarm for the Unit 2 turbine driven
auxiliary feedwater pump was received in the control room.
Operations personnel investigated the problem and found that the
3 KVA uninterruptible power system.(UPS) had failed due to an
inoperative transformer in an inverter to 'the UPS.
This
resulted in:the turbine driven pump being inoperative since the
UPS supplies control power to the pump control panel,-steam
admission. valves to the turbine, and power to the pump speed
controller.
The inoperative transformer was replaced and the
UPS and turbine driven auxiliary feedwater pump were
functionally tested and returned to service on September 1, 1987
at 12:30 a.m.
The action statement of the Technical
Specifications was met while this pump was out of service since
the remaining two auxiliary feedwater pumps were operable and
the inoperable pump was restored to operable status within 72
hours after the pump was found to be inoperable.
The inspectors had no further questions.
(3) Cross Train Service Water Cooling to the Unit 2 Battery Charger
Room Coolers
On September 3,1987, whil: replacing carbon steel piping with
stainless steel piping to the room coolers connected to the
service water system, the licensee noted that the Unit 2 "A"
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battery charger room cooler was supplied by the
"B" train
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service water system.
This situation was reported to the
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resident inspectors and Region II on September 4,1987.
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justification for continued operation (JC0) was prepared by the
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licensee and reviewed by the inspectors.
In general the JC0
indicated that proper cooling could be provided as long as both
service water trains remain operational.
In the event one train
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is lost, sufficient cooling should be provided by keeping one of
the doors between the "C" battery charger room and either the
"A" or "B" charger room open.
If additional' cooling would be
required sections of ducting from the "C" train cooler and the
affected train cooler could be removed and ventilation dampers
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closed to aid in cooling the affected charger room.
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Furthermore, a study made by the licensee in 1984 indicated that
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it would take over 28 hours3.240741e-4 days <br />0.00778 hours <br />4.62963e-5 weeks <br />1.0654e-5 months <br /> before the temperature in one of the
' battery charger rooms would reach 120 F in the event that no
cooling was provided for the room.
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Presently, the licensee is evaluating this problem to determine
the corrective action to be taken and the date this action will
be completed.
The inspectors are reviewing this discrepancy to
determine the appropriate NRC action required.
This is
identified as Unresolved Item 348,364/87-23-02 pending
completion of this review.
b.
Radiological Protection Program (71709)
Selected activities of the licensee's Radiological Protection Program
were reviewed by the inspectors to verify conformance with plant
procedures and NRC regulatory requirements.
The areas reviewed
included the organization and management of the plant's health
physics staff; "ALARA" implementation; Radiation Work Permits (RWP's)
for compliance to plant procedures; personnel exposure records;
observation of work and personnel in radiation areas to verify
compliance to radiation protection procedures; and control of
radioactive materials.
The inspectors had no further questions at this time.
c.
Physical Security Program (71881)
The licensee's compliance to the approved security plan was reviewed
by the inspectors.
The inspectors verified by observation and
interviews with security force members that measures taken to assure
the physical protection of the facility met current requirements.
Areas inspected included:
organization of the security force;
establishment and maintenance of gates, doors, and isolation zones;
access control; and, badging procedures.
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The inspectors had no further questions at this time.
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Surveillance Observation (61726)
Portions of the fc11owing surveillance inspections and tests required by
the Technical Specifications were witnessed, observed or reviewed by the
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inspectors:
Operations Daily Shift Surveillance Requirements
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STP-1.0
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FSP-6.1
Low Pressure CO M nthly Test
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STP-22.16 - Turbine Driven Auxiliary Feedwater Pump Quarterly Test
Service Water Pumps 1A, 1B and 1C Annual Inservice Test
STP-24.3
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S1P-33.0A - Solid State Protection System Train A Operability Test
Diesel Generator 1-2A Operability Test
STP-80.1
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Diesel Generator 1C Operability lest
STP-80.2
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Diesel Generator 1B Operability Test
STP-80.5
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STP-612.0 - Reactor Coolant Pump Bus Reactor Trip Undervoltage
Calibration
Pressurizer Heater Quarterly Check
STP-638
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STP-71.0 - Main Control Room Remote Valve Verification
No violations or deviations were identified.
However, in reviewing the
completed surveillance
on the electrical test procedures, it was noted
that it took an excessive time period for the procedures to complete the
management review.
For example, the most current completed copy of
monthly surveillance procedure 1-STP-638 within document control center
was the surveillance completed on September 18, 1986.
The data on 10 of
the 33 surveillance conducted in 1986 and all of the 1987 surveillance
were still in the review chain.
For procedure 1-STP-612, only 3 c.ompleted
procedures for 1986 and 1987 were in the document control center.
This
was also identified by the Safety Audit Engineering Review (SAER) Group
during the August 1987 Annual Electrical and Mechanical Maintenance
Surveillance Test Program audit as noncompliance FNP-NC-121-87.
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Therefore, a violation on this licensee identified item will not be
issued.
The inspectors will follow and review the licensee's corrective
action.
7.
Monthly Maintenance Observation (62703)
The inspectors observed / reviewed the following maintenance activities of
safety-related systems and components to ascertain that they were
conducted in accordance with approved procedures, regulatory guides,
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industry codes and standards, and were in conformance with Technical
Specifications:
Replacement of transformer in uninterruptible power supply system
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(UPS) for Unit 2 turbine driven auxiliary feedwater pump (MWR
139219).
Re-terminate motor leads on motor operated valves to meet
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environmental qualification criteria (MWR Nos. 139108, 139139, 139170
and 139172).
Inspection of Model DS-416 Westinghouse breakers for weld cracks for
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reactor trip by-pass breakers (MWR Nos. 137489, 137490, 137493 and
137494).
Replacement of deteriorated underground hydrogen piping (MWR 149559).
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Installation of control room carpet (Purchase Order Nos. 69527 and
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69528).
Replacement of service water pump 2C (MWR 154100)
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The following procedures were reviewed:
Termination of Environmental Qualified Motors using
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Raychem Motor Correction Kits.
Inspection Procedure for Raychem Heat Shrink
ETP-4251
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Connection.
Items considered during the review included: verification that limiting
conditions for operations were met while components or systems were
removed from service; approvals were obtained prior to initiating the
work; approved procedures were used; completed work was inspected as
applicable; functional testing and/or calibrations were performed prior to
returning components or systems to service; quality control records were
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maintained; activities were accomplished by qualified personnel; parts and
materials were properly certified; and, radiological and fire prevention
controls were implemented.
Work requests were also reviewed to determine
the status of outstanding jobs to assure that priority was assigned to
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safety-related equipment maintenance which may affect system performance.
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No discrepancies were identified. However, the activities associated with
re-terminating electrical leads to solenoid and motor operated valves and
to motors associated with containment building hydrogen mixing and
containment building cooling continued to be performed during this
inspection period.
These were previously identified as unresolved Items
348,364/87-17-01, 02, and 03 and remain open pending further review and
evaluation by the NRC.
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On August 29, 1987, the licensee inspected the reactor trip bypass
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breakers for weld cracks in respeau to NRC Information Notice 87-35.
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weld cracks were identified and breakers were functionally tested by
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cycling the breakers closed and open prior to returning to service.
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main reactor trip breakers are to be inspected at a later date.
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8.
Engineered Safety Systems Inspections (71710)
The inspectors performed various system inspections during the inspection
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period.
Overall plant conditions were assessed with particular attention
to equipment condition, radiological controls, security, safety, adherence
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to technical specification requirements, systems valve alignment, and
locked valve verification.
Major components were checked for leakage and
any general conditions that would degrade performance or prevent
fulfillment of functional requirements.
The inspectors verified that
approved procedures and up-to-date drawings were used.
Portions of the following systems were observed for proper operation,
valve alignment and valve verification:
Auxiliary Feedwater Systems
Chemical Volume Control Systems
Service Water Systems
Boric Acid Transfer Systems
Containment Spray System Including Chemical Additive System
Residual Heat Removal System
The systems were accessed to be operable in accordance with the Technical
Specifications, appropriate drawings, procedures, and the Final Safety
Analysis Report.
No violations or deviations were identified.
9.
Enforcement Conference Meeting
On September 3, 1987, an Enforcement Conference was held in the offices of
Region II to discuss potential enforcement findings which were identified
during an inspection conducted by the Vendor Inspection Branch at Farley
Nuclear Plant on May 11-22 and June 1-5, 1987.
Attendees at the
Enforcement Conference are attached.
Dr. J. N. Grace opened the meeting by reviewing the NRC concerns.
Mr. R. P. Mcdonald presented the Alabama Power Company introductory
statement.
Mr. J. D. Woodard discussed the Vendor Inspection Branch
findings in detail as they relate to Farley Nuclear Plant.
Mr. Woodard was
assisted in his discussion by Mr. W. G. Hairston III, Vice President,
Nuclear Generation;
L. A. Ward, Maintenance Manager; D. M. Stinson,
Modifications Manager; and R. D. Hill, Operations Manager.
The items discussed by Alabama Power Company included improper
installation of the "B" train service water battery racks; major safety
related procurement and installation of nine circuit breakers without
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verification of the vendor - basis for seismic qualification and for
upgrading the' circuit breaker voltage rating from 480 volts to.600 volts;
commercial grade ~ items which were procured and installed into
' safety-related and/or environmentally qualified systems without adequate
evaluation for suitability of application; inadequate corrective action on
-five vendor. related issues;. and deportability. of. cracked battery cells in
the auxiliary building train
"A" and'"B" 125 V DC system and inoperable
fire dampers in _the control. room ventilation system.
Although
acknowledging certain personnel errors, the licensee stated and gave their-
evaluation that the systems would have performed their. safety function 'if
they'had been called upon.
At the conclusion of the conference the NRC agreed to review certain other
procurement documents which Alabama Power Company would make available.
Mr. R. P. Mcdonald gave his closing remarks that they. take seriously all
issues discussed in this conference and that Alab'ama Power Company would
continue their . review of these issues.
Dr. J. N. Grace thanked the
licensee for the presentation.and stated that the exchange of views was
beneficial and the matter would be further reviewed by the NRC.
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ENFORCEMENT CGNFERENCE' ATTENDEES
Name-
Organization.
Position
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NRC Employees
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W. H. Bradford
RII
Senior Resident Inspector
N. Merriweather
RII
Electrical Engineer
B. Urycf
RII
Enforcement Coordinator.
~J.
Luehman-
RII
Senior.En. Specialist
G.:R.-Jenkins
.RII
Director, EICS
W. Troskoski.
OED0
E. W. Merschoff-
Vendor Branch Chief
R. P. McIntyre
Vendor. Branch Inspector
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D. M. Verre111
RII
Branch Chief, DRP
J..N.. Grace
RII
Regional Administrator
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E.-G. Adensam
Project Director
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A. F. Gibson
RII
Director, DRS
C. J. Paulk
RII
Engineer
T. E. Conlon-
RII
Section Chief-DRS
A. R. Herdt
RII
Branch' Chief, DRS
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G..A.'Belisle-
RII
Section Chief, DRS
A. B. Ruff
RII
Engineer
APC Employees
L. A.' Ward
APC0
Manager, Maintenance
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L. M. Stinson
APC0
Manager, Plant Modifications
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J. W. McGowan
APC0
Manager Safety Audit Eng.
R. D. Hill
APC0
Operations Manager.
W. G. Hairston:
APC0
Vice President Nuclear Support
'R..P. Mcdonald
APC0
Senior V.P. Alabama Power
W. B. Shipman
APC0
Assistant Plant Manager
J. D. Woodard
APC0
Plant Manager
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