ML20235U944

Insp Repts 50-348/87-23 & 50-364/87-23 on 870818-0910. Violations Noted.Major Areas Inspected:Surveillance Observation,Monthly Maint Observation,Operational Safety Verification & Physical Security Program

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: ML20235U916 ML20235U935 ML20235U944
References
50-348-87-23, 50-364-87-23, NUDOCS 8710140327
Download: ML20235U944 (10)

See also: IR 05000348/1987023

Text

pm uog UNITED STATES

g *o NUCLEAR REGULATORY COMMISSION

p - f[ n REGION 11

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101 MARIETTA STREET, N.W.

c 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 l

600 North 18th Street '

Birmingham, AL 35291  ;

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Docket Nos.: 50-348 and 50-364 License Nos.: NPF-2 and NPF-8

Facility name: Farley 1 and 2

Inspection Conducted: August 18 - September 10, 1987

Inspection at Farley site near Dothan, Alabama

Inspec ors: #W / / [7

W'. H. B r d f o rd Date Signed

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W.'

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MilUer, Jr.

V Hff f57

Date si ned

Approved by:

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H. C. Dance, Section Chief

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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 i

C. D. Nesbitt, Technical Manager .

R. G. Berryhill, Systems Performance and Planning Manager  !

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 ,

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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.5.. ' Operational . Safety Verification

a. 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

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discussions provided a daily status _of' plant operations', maintenance,

and testing activities in progress, as well as discussions of

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significant problems.

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 ,

which indicate that normal air pressure is available in the air l"

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 i

accordance with tha plant design documents, Unit 1 j

Instrumentation Set Point Index A-170750, and Unit 2 Set Point i

Index 205968. The documents required the set points for the j

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 ,

psig. The set points for diesel generator Nos. 1C and 2C were  !

required to be set at 240 psig and to remain locked in position l

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 and to open at various points ranging from 406 to 422 ps psig +Ig

in lieu of the required 420 and 370 psig set points. The i

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 ,

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

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

service water system. This situation was reported to the f,

resident inspectors and Region II on September 4,1987. A )

justification for continued operation (JC0) was prepared by the i

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 i

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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  !

closed to aid in cooling the affected charger room. l

Furthermore, a study made by the licensee in 1984 indicated that 1

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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'6.. Surveillance Observation (61726)

Portions of the fc11owing surveillance inspections and tests required by

the Technical Specifications were witnessed, observed or reviewed by the l

inspectors:

STP-1.0 - Operations Daily Shift Surveillance Requirements )

FSP-6.1 - Low Pressure CO M nthly Test j

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STP-22.16 - Turbine Driven Auxiliary Feedwater Pump Quarterly Test

STP-24.3 - Service Water Pumps 1A, 1B and 1C Annual Inservice Test

S1P-33.0A - Solid State Protection System Train A Operability Test

STP-80.1 - Diesel Generator 1-2A Operability Test

STP-80.2 - Diesel Generator 1C Operability lest

STP-80.5 - Diesel Generator 1B Operability Test

STP-612.0 - Reactor Coolant Pump Bus Reactor Trip Undervoltage

Calibration

STP-638 - Pressurizer Heater Quarterly Check

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. <

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

(UPS) for Unit 2 turbine driven auxiliary feedwater pump (MWR

139219).

- Re-terminate motor leads on motor operated valves to meet

environmental qualification criteria (MWR Nos. 139108, 139139, 139170

and 139172).

- Inspection of Model DS-416 Westinghouse breakers for weld cracks for

reactor trip by-pass breakers (MWR Nos. 137489, 137490, 137493 and

137494).

- Replacement of deteriorated underground hydrogen piping (MWR 149559).

- Installation of control room carpet (Purchase Order Nos. 69527 and

69528).

- Replacement of service water pump 2C (MWR 154100)

The following procedures were reviewed:

MP-91.0 - Termination of Environmental Qualified Motors using

Raychem Motor Correction Kits.

ETP-4251 - Inspection Procedure for Raychem Heat Shrink

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

maintained; activities were accomplished by qualified personnel; parts and I

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 j

safety-related equipment maintenance which may affect system performance. I

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 I

breakers for weld cracks in respeau to NRC Information Notice 87-35. No j

weld cracks were identified and breakers were functionally tested by '

cycling the breakers closed and open prior to returning to service. The i

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  !

period. Overall plant conditions were assessed with particular attention

to equipment condition, radiological controls, security, safety, adherence i

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

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Name- Organization. Position

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. NRR OED0

E. W. Merschoff- NRR Vendor Branch Chief

R. P. McIntyre

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NRR Vendor. Branch Inspector

D. M. Verre111 RII Branch Chief, DRP

J..N.. Grace RII Regional Administrator

l E.-G. Adensam NRR 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 4

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L. M. Stinson APC0 Manager, Plant Modifications

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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