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{{#Wiki_filter:I)NRCFORM366{61688)U.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAMEi1)R.E.GinnaNuclearPowerPlantLICENSEEEVENTREPORT(LER){Seereverseforrequirednumberofdigits/charactersforeachblock)PAGEI3)1OF7DOCKETNUMBERl2)050002448"ICPYPP"Bth''PILew(P"informationcollectionrequest:50hrs.Reportedlessonslearnedareincorporatedintothelicensingprocessandfedbacktoindustry.ForwardcommentsregardingburdenestimatetotheRecordsManagementBranch(TRF33),U.S.NuclearRegulatoryCommission,Washington.DC205554001~andtothePapenvorkReductionProject{3150%104),OfficeofManagementandBudget,Washington,DC20503.IfaninformationcollectiondoesnotdisplayacurrentlyvalidOMBcontrolnumber,theNRCmaynotconductorsponsor.andaTITlE(4)ContainmentRecirculationFanMoistureSeparatorVanesIncorrectlyInstalledResultsinPlantBeingOutsideItsDesignBasisEVENTDATE(5ILERNUMBER{6)REPORTDATE(7)OTHERFACILITIESINVOLVED{6)MONTHDAYYEARYEARSEOUENTIALNUMBERREYLSIONNUMBERMONTHOAYYEARFACILITYNAMEDOCKETNUMBER05000041219991999-004-0108241999FACILITYNAMEDOCKETNUMBER05000OPERATINGMODE(9)POWERLEVEL(10)000THISREPORTISSUBMITTEDP20.2201(b)20.2203(a)(T)20.2203(a)(2)(i)20.2203(a)(2)(ii)URSUANTTOTHEREQUIREMENTSOF10CFRE:(Check50.73(a)(2){i)(B)20.2203(a)(2)(v)20.2203(a){3)(i)20.2203(a)(3)(ii)20.2203(a)(4)X50.73{a)(2)(ii)50.73(a)(2){iii)50.73(a)(2)(iv)oneormore)(11)50.73(a)(2)(viii)50.73(a)(2)(x)73.71OTHER20.2203(a)(2)(iii)20.2203(a)(2)(iv)50.36(c)(1)50.36(c)(2)LICENSEECONTACTFORTHISLER{12)50.73(a){2)(v)50.73(a)(2){vii)SpecifylnAbstractbeloworinNRCForm366ANAMETELEPHONENUMBER(IiciudeAreaCode)CarmenVitali-SeniorEngineer(716)771-3606CAUSESYSTEMCOMPONENTMANUFACTURERREPORTABLETOEPIXIln>.CAUSESYSTEMCOMPONENTMANUFACTURERREPORTABIETOEPIXSUPPLEMENTALREPORTEXPECTED(14)YES(Ifyes,completeEXPECTEDSUBMISSIONDATE).XNoEXPECTEDSUBMISSIONDATE(15)MONTHOAYYEARABSTRACT{Limitto1400spaces,i.e.,approximately15single-spacedtypewrittenlines)(16)OnApril12,1999,atapproximately1600EDST,theplantwasshutdowninMode5.Itwasdiscoveredthatthecontainmentrecirculationfanchevronmoistureseparatorvaneswereinstalledbackwards,sothatthepathforairflowwaslesstortuous,decreasingmoistureseparationeffectiveness.Correctiveactionwastoremovethevanesandinstallthemintheproperorientation.Theincorrectinstallationwasaresultofimproperassemblybythemanufacturerinthe1960's.Theoriginalmoistureremovalequipmentconsistedofanassemblymadeupofthechevrontypevanesandfiberglassmoistureremovalpads.Thisequipmentwasshop-assembledandshippedtoGinnaStation.Vendorphotographstakenduringoriginalshopassemblyshowthevanesinstalledinamannernowknowntobeincorrect.CorrectiveactiontopreventrecurrenceisoutlinedinSectionV.99090i0030990E)24PDRADOCK050002448PDR NRCFORM366A(6.1998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARSEIIUENTIAENUMBERNUMBER1999-004-01PAGE(3)2OF7TEXTiifmorespaceisrequired,useadditionalcopiesofhfRCForm366AI(17)PRE-EVENTPLANTCONDITIONS:OnApril12,1999,theplantwasshutdowninMode5forthe1999refuelingoutage.Amongthemanyactivitiesinprogressduringthe1999refuelingoutage,maintenancewasbeingperformedontheContainmentRecirculationFanCoolers(CRFC)~Atapproximately1600EDST,anengineerfromNuclearEngineeringServices(NES)discoveredthatthechevronmoistureseparatorvanesfortheCRFCswereinstalledcontrarytothatshowninavendormanualdiagram,butcorrectlyasshownonavendoroutlinedrawing.DESCRIPTIONOFEVENT:A.DATESANDAPPROXIMATETIMESOFMAJOROCCURRENCES:oOriginalconstructioncirca1969:Eventdateandtime.oApril12,1999,1600EDST:Discoverydateandtime.oApril17,1999,1000EDST:Chevronmoistureseparatorvanesarecorrectlyinstalled.B..EVENT:OnApril12,1999,theplantwasshutdowninMode5forthe1999refuelingoutage.Amongthemanyactivitiesinprogressduringthe1999refuelingoutage,maintenancewasbeingperformedontheContainmentRecirculationFanCoolers(CRFC).Atapproximately1600EDST,anengineerfromNuclearEngineeringServices(NES)discoveredthatthechevronmoistureseparatorvanesfortheCRFCswereinstalledcontrarytothatshownonavendormanualdiagram,butcorrectlyasshownonavendoroutlinedrawing.Afterfurtherevaluationanddiscussionswiththevendor,itwasconcludedthatthevaneswereinstalledbackwards,sothatthepathforairflowislesstortuousthanifthevaneswerecorrectlyinstalled.ThesevanesareTypeTMistExtractors,manufacturedbyAmericanAirFilterCo.,Inc.TheCRFCSystemconsistsoffourfanunits(A,B,C,andD),ofwhichtheAandCunitssupplycharcoalfilters.Eachcoolingunitconsistsofamotor,fan,coolingcoils,dampers,moistureseparators(vanesandpads),highefficiencyparticulateair(HEPA)filters,ductdistributorsandnecessaryinstrumentationandcontrols.Airisdrawnintothecoolersthroughthefananddischargedintothecontainmentatmosphere.ThemoistureseparatorsfunctiontoreducethemoisturecontentoftheairstreamtosupporttheeffectivenessoftheHEPAandpost-accidentcharcoalfilters.
{{#Wiki_filter:I)NRCFORM366{61688)U.S.NUCLEARREGULATORY COMMISSION FACILITYNAMEi1)R.E.GinnaNuclearPowerPlantLICENSEEEVENTREPORT(LER){Seereverseforrequirednumberofdigits/characters foreachblock)PAGEI3)1OF7DOCKETNUMBERl2)050002448"ICPYPP"Bth''PILew(P"information collection request:50hrs.Reportedlessonslearnedareincorporated intothelicensing processandfedbacktoindustry.
NRCFORM366A(61998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMIVIISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)rEANSEGUENTNLNUMUENNUMSEA1999-004-01PAGE(3)3OF7TEXT(Ifmorespaceisrequired,useadditionalcopiesofNRCForm366AI(17)Followingthecoolingcoilsisthemoistureseparatorsection,designedtoremoveentrainedmoistureexitingthecoolingcoils.Twoseparatemoistureremovalprocessesareemployed;thefirstbydirectimpingementonverticalhookedvanes,andthesecondbytrappingonseparatorpads.Runofffrombothstagesflowsintocollectionpansfromwhichitispipedtothecontainmentsump.Themoistureseparatorcasings,hookedvanes,andcollectionpansarefabricatedofgalvanizedsteel.Withthevanesinstalledbackwards,themoistureseparationcapabilityisdecreased.CRFCperformancewasnotcompletelyanalyzedforthiscondition.Thesupplierofthemoistureremovalequipment(AmericanAirFilter)wascontacted.Itwasconcludedthatthisconditionwasaresultofimproperassemblybythemanufacturerinthe1960's.Theoriginalmoistureremovalequipmentconsistedofanassemblymadeupofthechevrontypevanesandfiberglassmoistureremovalpads.Thisequipmentwasshop-assembledandshippedtoGinnaStation.Vendorphotographstakenduringoriginalshopassemblyshowthevanesinstalledinamannernowknowntobeincorrect.Asdirectedbythesupplier,thevaneshadtobedismantledandthencorrectlyinstalled.C.INOPERABLESTRUCTURES,COMPONENTS,ORSYSTEMSTHATCONTRIBUTEDTOTHEEVENT:NoneD.OTHERSYSTEMSORSECONDARYFUNCTIONSAFFECTED:NoneE.METHODOFDISCOVERY:ThiseventwasdiscoveredbyanengineerfromNES,whowassupportingCRFCmaintenance.F.OPERATORACTION:TheplantwasinMode5atthetimeofdiscovery,andtheCRFCsarenotrequiredtobeoperableinthismode.AftertheNESengineernotifiedtheShiftSupervisorofthiscondition,noimmediateactionswereneededbytheControlRoomoperators.Subsequently,theShiftSupervisornotifiedhighersupervisionandtheNRCGinnaSeniorResidentInspector.TheShiftSupervisornotifiedtheNRCper10CFR50.72(b)(2)(i),non-emergencyfourhournotification,atapproximately1948EDSTonApril12,1999.G.SAFETYSYSTEMRESPONSES:None NRCFORM366AISIB98)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAMEI1)R.E.GinnaNuclearPowerPlantDOCKETI2)05000244LERNUMBERIB)TEARSEQUENTIALREVISIQNNUMBERNUMBER1999-OP4..O1PAGEI3)4OF7TEXTllfmorespaceisrequired,useadditionalcopiesofNRCForm366'17)III.CAUSEOFEVENT:A.IMMEDIATECAUSE:Theimmediatecauseoftheplantpossiblyoperatingoutsideitsdesignbasiswasthattheinstalledconfigurationresultedindecreasedmoistureseparationcapabilityafteradesignbasisaccident,resultinginlesscoolingcapability.B.INTERMEDIATECAUSE'heintermediatecausewasinstallationofimproperlyassembledmoistureseparatorunits.Theoriginalmoistureremovalunitsconsistedofassembliesmadeupofthechevrontypevanesandfiberglassmoistureremovalpads.Thisequipmentwasshop-assembledandshippedtoGinnaStation.Vendorphotographstakenduringoriginalshopassemblyshowthevanesinstalledinamannernowknowntobeincorrect.C.ROOTCAUSE:Theunderlyingcauseofthevanesbeinginstalledbackwardswasamanufacturingerror.IV.ANALYSISOFEVENT:Thiseventisreportableinaccordancewith10CFR50.73,LicenseeEventReportSystem,item(a)(2)(ii)(B),whichrequiresareportof,"Anyeventorconditionthatresultedintheconditionofthenuclearpowerplant,includingitsprincipalsafetybarriers,beingseriouslydegraded;orthatresultedinthenuclearpowerplantbeing:(B)Inaconditionthatisoutsidethedesignbasisoftheplant.Anassessmentwasperformedconsideringboththesafetyconsequencesandimplicationsofthiseventwiththefollowingresultsandconclusions:Therewerenooperationalorsafetyconsequencesorimplicationsattributedtothemoistureseparatorvanesinstalledbackwardsbecause:Themaximumairvelocitythroughthecontainmentrecirculationfancoolingcoilsafteraloss-of-coolantaccident(LOCA)airvelocitythroughthecoilisbelowtheAmerican'SocietyofHeating,RefrigeratingandAir-ConditioningEngineers(ASHRAE)thresholdof600feetperminute(FPM)formoistureentrainmentbothforthenewandoldconfiguration.Thecoilswillactasmoistureseparatorsduetothedepthofthecoilandspacingbetweenfins,eveniftheyarenotoperating.AheatingcoilsimilartothecoolingcoilsinstalledatGinna,wastestedwithaspraystreamequivalenttotheGinnaStationLOCAenvironmentdirectedatthecoilentrance,butwithaslightlylowerairstreamvelocity(400FPM)thanGinna.Nomoisturecarry-overwasobservedontheoutletofthecoiloronthemoistureseparatordownstreamofthecoil.Approximately5%ofthespraywasevaporatedbythecoilheating.
Forwardcommentsregarding burdenestimatetotheRecordsManagement Branch(TRF33),U.S.NuclearRegulatory Commission, Washington.
NRCFORM366A(91998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)"TEARSEOUENTIALREUISIONNUMBERNUMBER1999-004-01PAGE(3)6OF7TEXTIifmorespaceisrequired,useadditionalcopiesofNRCForm366AI(17)Additionallouversarelocatedontheinlettothecoilswhichwillremovesomeentrainedmoisturepriortoenteringthecoolingcoils,whicharenottakencreditforintheCRFCunitoperation.Theairvelocitysignificantlyreducesafterexitfromthecoolingcoils,andwouldallowentraineddropletstofalltothefanunitfloorpriortoreachingtheHEPAfilterswhicharelocatedapproximately6feetfromthecoolingcoils.0ThemoistureseparatormediapadslocatedupstreamoftheHEPAfiltershavebeentestedandfoundtoremovemoistureupto1.5Ibs/100cu.ft.ThemaximumexpectedentrainedmoisturecontentinthecontainmentenvironmentduetocontainmentsprayandcondensationisonlyOAIbs/1000cu.ft.TheoriginalmediapadsinstalledatGinna(AmericanAirFilterModelM-105)werereplacedwithnewmodelM-81padsthathavenotbeentestedtoGinnaLOCAconditions.However,duetosimilaritiesindesign,theyareexpectedtoremainfunctionaleventhoughtheyhavenotbeencreditedtofunctionduetolackofqualification.Themoistureseparatorvanesontheoutletofthecoilwouldstillremoveentrainedwatereventhoughtheyareinstalledbackwards,duetotheirtortuouspath.Thenumberofhookswhichprotrudeintotheflowstreamisreducedfrom3to1.However,themoistureremovalisdominatedbythespacingbetweenadjacentvanes,lengthofeachvaneandnumberofvaneturnsinpath,allofwhichareunaffectedwiththevanesinstalledbackwards.Thewaterdropsfollowasine-wavepaththroughthevanes.Theoverallefficiencyforthebackwardsinstallationisestimatedtobe25%.ThemoistureremovalcapacityrequirementasspecifiedintheoriginalBillofMaterialsforthemoistureremovalsectionoftheCRFCunitis0.4Ibs/1000cu.ft.This25%reductioninthevaneefficiencycanbeeasilycompensatedforbythemoistureremovalpadssincetheyweretestedatmoisturelevelsofgreaterthan1.0Ibs/1000cu.ft.Inaddition,theHEPAfilterswerealsotestedandtheirpressuredropincreasedby0.5incheswithanequivalentmoistureloadingofOAIbs/1000cu.ft.Itisbelievedthattheadditional0.5inchesofpressurelossiswithintheexistingmarginoftheas-installedequipmentandwouldresultinreductionintotalsystemCRFCflowoflessthan10%0ThemainimpactofaslightlyreducedCRFCcoolingcapabilityonthedesignbasisaccidents(DBAs)suchasLOCAsandMainSteamLineBreaks(MSLBs)wouldbeareductioninthelongtermcoolinganddepressurizationcapabilityofcontainment.ImpactonpeakcontainmentpressuresforDBAsisexpectedtobenegligible.SincepeakcontainmentpressurestypicallyoccurwithinthefirstcoupleofminutesfollowingDBAs,theincreaseinHEPAfilterhydraulicresistancewouldnotbefullydevelopedoverthistimeduetothelimitedwaterloadingontheHEPAfiltersimmediatelyfollowingaDBA.Additionally,theearlyoccurrenceofcontainmentpeakpressureslimitstheintegratedamountofenergythatisremovedbytheCRFCsuptothetimeofpeakcontainmentpressure.Therefore,anydegradationinCRFCheatremovalcapabilityduetoreducedairsideflowimmediatelyfollowingaDBAwouldhaveanegligibleimpactontheoverallcontainmentenergybalanceatthetimeofpeakcontainmentpressure.Baseduponthesefactors,anyincreaseinpeakcontainmentpressurethatcouldhaveoccurredasaresultoftheimproperlyinstalledlouversisjudgedtobewithintheoverallstructuralcapabilityofthecontainmentfollowingaDBA,althoughcontainmentdesignpressuremayhavebeenslightlyexceeded.
DC205554001
r NRCFORM366A(61968)LlCENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARBEOUENTNLNUMBERNUN'IBER1999-004-01PAGE(3)6OF7TEXTIlfmorespaceisrequired,useadditionalcopiesofNRCForm366AI(17)Aspreviouslystated,themajorimpactofreducedheatremovalcapabilityduetowaterloadingoftheHEPAfilterswouldbeonlongtermcontainmentcooling,sinceContainmentSprayflowisterminatedaftertheplanthastransitionedtotheRecirculationModeofcooling.AnyreductioninCRFCcoolingcapabilityduetoreducedairflowwouldcauseaslowercontainmentcoodownanddepressurization.AlthoughthisslowercontainmentcooldowncouldpotentiallyaffecttheEquipmentQualification(EQ)profilesofsafety-relatedequipmentincontainment,areviewoftheexistingGinnaEQprofilesforcontainmentindicatesthatsufficientmarginexistsduringthefirsttwenty-fourhoursfollowingaDBAtoaccommodateaslowercooldown.Consequently,noadverseimpactonpastoperabilityofqualifiedequipmentincontainmentisexpectedtohaveexisted.oTheGinnaControlRoomandoff-sitedosecalculationswerere-evaluatedassumingactualcontainmentintegratedleakagefromtestingperformedin1996andactualpredictedcontainmentdepressurizationratesforGinna.BasedontheseassumptionsandcontinuousoperationoftheCRFCsinapost-LOCAenvironment,itisestimatedthataminimumcharcoalfilteriodineremovalefficiencyof10%wouldberequiredtomaintainoff-sitedosesbelow300RemandControlRoomthyroiddosesbelow30RemandtherebysatisfytheGinnalicensingbasisrequirementasrequiredby10CFR100andGeneralDesignCriterion(GDC)19.BasedonadditionalanalysisthatwasperformedbyRG(ltEin1999,charcoalfilterswerefoundtohave40%oftheirvolumestillavailableforiodineremovalevenwhen100%saturated.Sincetheminimumrequiredcharcoaliodineremovalefficiencyisappreciablysmallerthantheminimumexpectedcharcoalefficiencyof40%forawettedcondition,thedesignfunctionofthefiltersasitrelatestothyroidsdosetoon-siteandoff-sitepersonnelwouldstillhavebeensatisfiedevenwiththelouversinstalledbackwards.Basedontheaboveandthereviewofpastplanttransients,itcanbeconcludedthatthepublic'shealthandsafetywasassuredatalltimes.V.CORRECTIVEACTION:A.ACTIONTAKENTORETURNAFFECTEDSYSTEMSTOPRE-EVENTNORMALSTATUS:Themoistureseparatorvanesweredismantledandcorrectlyre-installed.B.ACTIONTAKENORPLANNEDTOPREVENTRECURRENCE:Theas-leftconfigurationofthemoistureseparatorunitsdoesnotallowthevanestobeinstalledincorrectly.VI.ADDITIONALINFORMATION:A.FAILEDCOMPONENTS:None  
~andtothePapenvork Reduction Project{3150%104),
OfficeofManagement andBudget,Washington, DC20503.Ifaninformation collection doesnotdisplayacurrently validOMBcontrolnumber,theNRCmaynotconductorsponsor.andaTITlE(4)Containment Recirculation FanMoistureSeparator VanesIncorrectly Installed ResultsinPlantBeingOutsideItsDesignBasisEVENTDATE(5ILERNUMBER{6)REPORTDATE(7)OTHERFACILITIES INVOLVED{6)MONTHDAYYEARYEARSEOUENTIAL NUMBERREYLSIONNUMBERMONTHOAYYEARFACILITYNAMEDOCKETNUMBER05000041219991999-004-0108241999FACILITYNAMEDOCKETNUMBER05000OPERATING MODE(9)POWERLEVEL(10)000THISREPORTISSUBMITTED P20.2201(b) 20.2203(a)(T) 20.2203(a)(2)
(i)20.2203(a)(2)(ii)
URSUANTTOTHEREQUIREMENTS OF10CFRE:(Check50.73(a)(2)
{i)(B)20.2203(a)
(2)(v)20.2203(a)
{3)(i)20.2203(a)(3)(ii) 20.2203(a)(4)
X50.73{a)(2)(ii) 50.73(a)(2){iii)50.73(a)(2)(iv) oneormore)(11)50.73(a)(2)(viii) 50.73(a)(2)(x) 73.71OTHER20.2203(a)
(2)(iii)20.2203(a)(2)
(iv)50.36(c)(1) 50.36(c)(2)LICENSEECONTACTFORTHISLER{12)50.73(a){2)(v)50.73(a)(2)
{vii)SpecifylnAbstractbeloworinNRCForm366ANAMETELEPHONE NUMBER(IiciudeAreaCode)CarmenVitali-SeniorEngineer(716)771-3606CAUSESYSTEMCOMPONENT MANUFACTURER REPORTABLE TOEPIXIln>.CAUSESYSTEMCOMPONENT MANUFACTURER REPORTABIE TOEPIXSUPPLEMENTAL REPORTEXPECTED(14)YES(Ifyes,completeEXPECTEDSUBMISSION DATE).XNoEXPECTEDSUBMISSION DATE(15)MONTHOAYYEARABSTRACT{Limitto1400spaces,i.e.,approximately 15single-spaced typewritten lines)(16)OnApril12,1999,atapproximately 1600EDST,theplantwasshutdowninMode5.Itwasdiscovered thatthecontainment recirculation fanchevronmoistureseparator vaneswereinstalled backwards, sothatthepathforairflowwaslesstortuous, decreasing moistureseparation effectiveness.
Corrective actionwastoremovethevanesandinstallthemintheproperorientation.
Theincorrect installation wasaresultofimproperassemblybythemanufacturer inthe1960's.Theoriginalmoistureremovalequipment consisted ofanassemblymadeupofthechevrontypevanesandfiberglass moistureremovalpads.Thisequipment wasshop-assembled andshippedtoGinnaStation.Vendorphotographs takenduringoriginalshopassemblyshowthevanesinstalled inamannernowknowntobeincorrect.
Corrective actiontopreventrecurrence isoutlinedinSectionV.99090i0030 990E)24PDRADOCK050002448PDR NRCFORM366A(6.1998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARSEIIUENTIAE NUMBERNUMBER1999-004-01PAGE(3)2OF7TEXTiifmorespaceisrequired, useadditional copiesofhfRCForm366AI(17)PRE-EVENT PLANTCONDITIONS:
OnApril12,1999,theplantwasshutdowninMode5forthe1999refueling outage.Amongthemanyactivities inprogressduringthe1999refueling outage,maintenance wasbeingperformed ontheContainment Recirculation FanCoolers(CRFC)~Atapproximately 1600EDST,anengineerfromNuclearEngineering Services(NES)discovered thatthechevronmoistureseparator vanesfortheCRFCswereinstalled contrarytothatshowninavendormanualdiagram,butcorrectly asshownonavendoroutlinedrawing.DESCRIPTION OFEVENT:A.DATESANDAPPROXIMATE TIMESOFMAJOROCCURRENCES:
oOriginalconstruction circa1969:Eventdateandtime.oApril12,1999,1600EDST:Discovery dateandtime.oApril17,1999,1000EDST:Chevronmoistureseparator vanesarecorrectly installed.
B..EVENT:OnApril12,1999,theplantwasshutdowninMode5forthe1999refueling outage.Amongthemanyactivities inprogressduringthe1999refueling outage,maintenance wasbeingperformed ontheContainment Recirculation FanCoolers(CRFC).Atapproximately 1600EDST,anengineerfromNuclearEngineering Services(NES)discovered thatthechevronmoistureseparator vanesfortheCRFCswereinstalled contrarytothatshownonavendormanualdiagram,butcorrectly asshownonavendoroutlinedrawing.Afterfurtherevaluation anddiscussions withthevendor,itwasconcluded thatthevaneswereinstalled backwards, sothatthepathforairflowislesstortuousthanifthevaneswerecorrectly installed.
ThesevanesareTypeTMistExtractors, manufactured byAmericanAirFilterCo.,Inc.TheCRFCSystemconsistsoffourfanunits(A,B,C,andD),ofwhichtheAandCunitssupplycharcoalfilters.Eachcoolingunitconsistsofamotor,fan,coolingcoils,dampers,moistureseparators (vanesandpads),highefficiency particulate air(HEPA)filters,ductdistributors andnecessary instrumentation andcontrols.
Airisdrawnintothecoolersthroughthefananddischarged intothecontainment atmosphere.
Themoistureseparators functiontoreducethemoisturecontentoftheairstream tosupporttheeffectiveness oftheHEPAandpost-accident charcoalfilters.
NRCFORM366A(61998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMIVIISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)rEANSEGUENTNL NUMUENNUMSEA1999-004-01PAGE(3)3OF7TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366AI(17)Following thecoolingcoilsisthemoistureseparator section,designedtoremoveentrained moistureexitingthecoolingcoils.Twoseparatemoistureremovalprocesses areemployed; thefirstbydirectimpingement onverticalhookedvanes,andthesecondbytrappingonseparator pads.Runofffrombothstagesflowsintocollection pansfromwhichitispipedtothecontainment sump.Themoistureseparator casings,hookedvanes,andcollection pansarefabricated ofgalvanized steel.Withthevanesinstalled backwards, themoistureseparation capability isdecreased.
CRFCperformance wasnotcompletely analyzedforthiscondition.
Thesupplierofthemoistureremovalequipment (American AirFilter)wascontacted.
Itwasconcluded thatthiscondition wasaresultofimproperassemblybythemanufacturer inthe1960's.Theoriginalmoistureremovalequipment consisted ofanassemblymadeupofthechevrontypevanesandfiberglass moistureremovalpads.Thisequipment wasshop-assembled andshippedtoGinnaStation.Vendorphotographs takenduringoriginalshopassemblyshowthevanesinstalled inamannernowknowntobeincorrect.
Asdirectedbythesupplier, thevaneshadtobedismantled andthencorrectly installed.
C.INOPERABLE STRUCTURES, COMPONENTS, ORSYSTEMSTHATCONTRIBUTED TOTHEEVENT:NoneD.OTHERSYSTEMSORSECONDARY FUNCTIONS AFFECTED:
NoneE.METHODOFDISCOVERY:
Thiseventwasdiscovered byanengineerfromNES,whowassupporting CRFCmaintenance.
F.OPERATORACTION:TheplantwasinMode5atthetimeofdiscovery, andtheCRFCsarenotrequiredtobeoperableinthismode.AftertheNESengineernotifiedtheShiftSupervisor ofthiscondition, noimmediate actionswereneededbytheControlRoomoperators.
Subsequently, theShiftSupervisor notifiedhighersupervision andtheNRCGinnaSeniorResidentInspector.
TheShiftSupervisor notifiedtheNRCper10CFR50.72(b)(2)(i),non-emergency fourhournotification, atapproximately 1948EDSTonApril12,1999.G.SAFETYSYSTEMRESPONSES:
None NRCFORM366AISIB98)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAMEI1)R.E.GinnaNuclearPowerPlantDOCKETI2)05000244LERNUMBERIB)TEARSEQUENTIAL REVISIQNNUMBERNUMBER1999-OP4..O1PAGEI3)4OF7TEXTllfmorespaceisrequired, useadditional copiesofNRCForm366'17)III.CAUSEOFEVENT:A.IMMEDIATE CAUSE:Theimmediate causeoftheplantpossiblyoperating outsideitsdesignbasiswasthattheinstalled configuration resultedindecreased moistureseparation capability afteradesignbasisaccident, resulting inlesscoolingcapability.
B.INTERMEDIATE CAUSE'heintermediate causewasinstallation ofimproperly assembled moistureseparator units.Theoriginalmoistureremovalunitsconsisted ofassemblies madeupofthechevrontypevanesandfiberglass moistureremovalpads.Thisequipment wasshop-assembled andshippedtoGinnaStation.Vendorphotographs takenduringoriginalshopassemblyshowthevanesinstalled inamannernowknowntobeincorrect.
C.ROOTCAUSE:Theunderlying causeofthevanesbeinginstalled backwards wasamanufacturing error.IV.ANALYSISOFEVENT:Thiseventisreportable inaccordance with10CFR50.73,LicenseeEventReportSystem,item(a)(2)(ii)(B),whichrequiresareportof,"Anyeventorcondition thatresultedinthecondition ofthenuclearpowerplant,including itsprincipal safetybarriers, beingseriously degraded; orthatresultedinthenuclearpowerplantbeing:(B)Inacondition thatisoutsidethedesignbasisoftheplant.Anassessment wasperformed considering boththesafetyconsequences andimplications ofthiseventwiththefollowing resultsandconclusions:
Therewerenooperational orsafetyconsequences orimplications attributed tothemoistureseparator vanesinstalled backwards because:Themaximumairvelocitythroughthecontainment recirculation fancoolingcoilsafteraloss-of-coolantaccident(LOCA)airvelocitythroughthecoilisbelowtheAmerican'Society ofHeating,Refrigerating andAir-Conditioning Engineers (ASHRAE)threshold of600feetperminute(FPM)formoistureentrainment bothforthenewandoldconfiguration.
Thecoilswillactasmoistureseparators duetothedepthofthecoilandspacingbetweenfins,eveniftheyarenotoperating
.Aheatingcoilsimilartothecoolingcoilsinstalled atGinna,wastestedwithaspraystreamequivalent totheGinnaStationLOCAenvironment directedatthecoilentrance, butwithaslightlylowerairstreamvelocity(400FPM)thanGinna.Nomoisturecarry-over wasobservedontheoutletofthecoiloronthemoistureseparator downstream ofthecoil.Approximately 5%ofthespraywasevaporated bythecoilheating.
NRCFORM366A(91998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)"TEARSEOUENTIAL REUISIONNUMBERNUMBER1999-004-01PAGE(3)6OF7TEXTIifmorespaceisrequired, useadditionalcopiesofNRCForm366AI(17)Additional louversarelocatedontheinlettothecoilswhichwillremovesomeentrained moisturepriortoenteringthecoolingcoils,whicharenottakencreditforintheCRFCunitoperation.
Theairvelocitysignificantly reducesafterexitfromthecoolingcoils,andwouldallowentrained dropletstofalltothefanunitfloorpriortoreachingtheHEPAfilterswhicharelocatedapproximately 6feetfromthecoolingcoils.0Themoistureseparator mediapadslocatedupstreamoftheHEPAfiltershavebeentestedandfoundtoremovemoistureupto1.5Ibs/100cu.ft.Themaximumexpectedentrained moisturecontentinthecontainment environment duetocontainment sprayandcondensation isonlyOAIbs/1000cu.ft.Theoriginalmediapadsinstalled atGinna(American AirFilterModelM-105)werereplacedwithnewmodelM-81padsthathavenotbeentestedtoGinnaLOCAconditions.
However,duetosimilarities indesign,theyareexpectedtoremainfunctional eventhoughtheyhavenotbeencreditedtofunctionduetolackofqualification.
Themoistureseparator vanesontheoutletofthecoilwouldstillremoveentrained watereventhoughtheyareinstalled backwards, duetotheirtortuouspath.Thenumberofhookswhichprotrudeintotheflowstreamisreducedfrom3to1.However,themoistureremovalisdominated bythespacingbetweenadjacentvanes,lengthofeachvaneandnumberofvaneturnsinpath,allofwhichareunaffected withthevanesinstalled backwards.
Thewaterdropsfollowasine-wave paththroughthevanes.Theoverallefficiency forthebackwards installation isestimated tobe25%.Themoistureremovalcapacityrequirement asspecified intheoriginalBillofMaterials forthemoistureremovalsectionoftheCRFCunitis0.4Ibs/1000cu.ft.This25%reduction inthevaneefficiency canbeeasilycompensated forbythemoistureremovalpadssincetheyweretestedatmoisturelevelsofgreaterthan1.0Ibs/1000cu.ft.Inaddition, theHEPAfilterswerealsotestedandtheirpressuredropincreased by0.5incheswithanequivalent moistureloadingofOAIbs/1000cu.ft.Itisbelievedthattheadditional 0.5inchesofpressurelossiswithintheexistingmarginoftheas-installed equipment andwouldresultinreduction intotalsystemCRFCflowoflessthan10%0ThemainimpactofaslightlyreducedCRFCcoolingcapability onthedesignbasisaccidents (DBAs)suchasLOCAsandMainSteamLineBreaks(MSLBs)wouldbeareduction inthelongtermcoolinganddepressurization capability ofcontainment.
Impactonpeakcontainment pressures forDBAsisexpectedtobenegligible.
Sincepeakcontainment pressures typically occurwithinthefirstcoupleofminutesfollowing DBAs,theincreaseinHEPAfilterhydraulic resistance wouldnotbefullydeveloped overthistimeduetothelimitedwaterloadingontheHEPAfiltersimmediately following aDBA.Additionally, theearlyoccurrence ofcontainment peakpressures limitstheintegrated amountofenergythatisremovedbytheCRFCsuptothetimeofpeakcontainment pressure.
Therefore, anydegradation inCRFCheatremovalcapability duetoreducedairsideflowimmediately following aDBAwouldhaveanegligible impactontheoverallcontainment energybalanceatthetimeofpeakcontainment pressure.
Baseduponthesefactors,anyincreaseinpeakcontainment pressurethatcouldhaveoccurredasaresultoftheimproperly installed louversisjudgedtobewithintheoverallstructural capability ofthecontainment following aDBA,althoughcontainment designpressuremayhavebeenslightlyexceeded.
r NRCFORM366A(61968)LlCENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARBEOUENTNL NUMBERNUN'IBER1999-004-01PAGE(3)6OF7TEXTIlfmorespaceisrequired, useadditional copiesofNRCForm366AI(17)Aspreviously stated,themajorimpactofreducedheatremovalcapability duetowaterloadingoftheHEPAfilterswouldbeonlongtermcontainment cooling,sinceContainment Sprayflowisterminated aftertheplanthastransitioned totheRecirculation Modeofcooling.Anyreduction inCRFCcoolingcapability duetoreducedairflowwouldcauseaslowercontainment coodownanddepressurization.
Althoughthisslowercontainment cooldowncouldpotentially affecttheEquipment Qualification (EQ)profilesofsafety-related equipment incontainment, areviewoftheexistingGinnaEQprofilesforcontainment indicates thatsufficient marginexistsduringthefirsttwenty-four hoursfollowing aDBAtoaccommodate aslowercooldown.
Consequently, noadverseimpactonpastoperability ofqualified equipment incontainment isexpectedtohaveexisted.oTheGinnaControlRoomandoff-sitedosecalculations werere-evaluated assumingactualcontainment integrated leakagefromtestingperformed in1996andactualpredicted containment depressurization ratesforGinna.Basedontheseassumptions andcontinuous operation oftheCRFCsinapost-LOCA environment, itisestimated thataminimumcharcoalfilteriodineremovalefficiency of10%wouldberequiredtomaintainoff-sitedosesbelow300RemandControlRoomthyroiddosesbelow30RemandtherebysatisfytheGinnalicensing basisrequirement asrequiredby10CFR100andGeneralDesignCriterion (GDC)19.Basedonadditional analysisthatwasperformed byRG(ltEin1999,charcoalfilterswerefoundtohave40%oftheirvolumestillavailable foriodineremovalevenwhen100%saturated.
Sincetheminimumrequiredcharcoaliodineremovalefficiency isappreciably smallerthantheminimumexpectedcharcoalefficiency of40%forawettedcondition, thedesignfunctionofthefiltersasitrelatestothyroidsdosetoon-siteandoff-sitepersonnel wouldstillhavebeensatisfied evenwiththelouversinstalled backwards.
Basedontheaboveandthereviewofpastplanttransients, itcanbeconcluded thatthepublic'shealthandsafetywasassuredatalltimes.V.CORRECTIVE ACTION:A.ACTIONTAKENTORETURNAFFECTEDSYSTEMSTOPRE-EVENT NORMALSTATUS:Themoistureseparator vanesweredismantled andcorrectly re-installed.
B.ACTIONTAKENORPLANNEDTOPREVENTRECURRENCE:
Theas-leftconfiguration ofthemoistureseparator unitsdoesnotallowthevanestobeinstalled incorrectly.
VI.ADDITIONAL INFORMATION:
A.FAILEDCOMPONENTS:
None  


NRCFORM366A(6.1898)LICENSEEEVENTREPORT(LER)TEXTCONTINUATIONU.S.NUCLEARREGULATORYCOMMISSIONFACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARSEOUENTIAEREVISIONNUMBERNUMBER1999-004-01PAGE(3)7OF7TEXT(Ifmorespaceisrequired,useadditionalcopiesofNRCForm366AJ(17)B.PREVIOUSLERsONSIMILAREVENTS:AsimilarLEReventhistoricalsearchwasconductedwiththefollowingresults:NodocumentationofsimilarLEReventswiththesamerootcauseatGinnaStationcouldbeidentified.C.SPECIALCOMMENTS:None}}
NRCFORM366A(6.1898)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARSEOUENTIAE REVISIONNUMBERNUMBER1999-004-01PAGE(3)7OF7TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366AJ(17)B.PREVIOUSLERsONSIMILAREVENTS:AsimilarLEReventhistorical searchwasconducted withthefollowing results:Nodocumentation ofsimilarLEReventswiththesamerootcauseatGinnaStationcouldbeidentified.
C.SPECIALCOMMENTS:
None}}

Revision as of 12:32, 29 June 2018

LER 99-004-01:on 990412,discovered That Containment Recirculation Fan Chevron Separator Vanes Were Installed Backwards.Caused by Improper Assembly by Mfg.Moisture Separator Vanes Were Dismantled & Correctly re-installed
ML17265A743
Person / Time
Site: Ginna Constellation icon.png
Issue date: 08/24/1999
From: VITALI C
ROCHESTER GAS & ELECTRIC CORP.
To:
Shared Package
ML17265A742 List:
References
LER-99-004, NUDOCS 9909010030
Download: ML17265A743 (9)


Text

I)NRCFORM366{61688)U.S.NUCLEARREGULATORY COMMISSION FACILITYNAMEi1)R.E.GinnaNuclearPowerPlantLICENSEEEVENTREPORT(LER){Seereverseforrequirednumberofdigits/characters foreachblock)PAGEI3)1OF7DOCKETNUMBERl2)050002448"ICPYPP"BthPILew(P"information collection request:50hrs.Reportedlessonslearnedareincorporated intothelicensing processandfedbacktoindustry.

Forwardcommentsregarding burdenestimatetotheRecordsManagement Branch(TRF33),U.S.NuclearRegulatory Commission, Washington.

DC205554001

~andtothePapenvork Reduction Project{3150%104),

OfficeofManagement andBudget,Washington, DC20503.Ifaninformation collection doesnotdisplayacurrently validOMBcontrolnumber,theNRCmaynotconductorsponsor.andaTITlE(4)Containment Recirculation FanMoistureSeparator VanesIncorrectly Installed ResultsinPlantBeingOutsideItsDesignBasisEVENTDATE(5ILERNUMBER{6)REPORTDATE(7)OTHERFACILITIES INVOLVED{6)MONTHDAYYEARYEARSEOUENTIAL NUMBERREYLSIONNUMBERMONTHOAYYEARFACILITYNAMEDOCKETNUMBER05000041219991999-004-0108241999FACILITYNAMEDOCKETNUMBER05000OPERATING MODE(9)POWERLEVEL(10)000THISREPORTISSUBMITTED P20.2201(b) 20.2203(a)(T) 20.2203(a)(2)

(i)20.2203(a)(2)(ii)

URSUANTTOTHEREQUIREMENTS OF10CFRE:(Check50.73(a)(2)

{i)(B)20.2203(a)

(2)(v)20.2203(a)

{3)(i)20.2203(a)(3)(ii) 20.2203(a)(4)

X50.73{a)(2)(ii) 50.73(a)(2){iii)50.73(a)(2)(iv) oneormore)(11)50.73(a)(2)(viii) 50.73(a)(2)(x) 73.71OTHER20.2203(a)

(2)(iii)20.2203(a)(2)

(iv)50.36(c)(1) 50.36(c)(2)LICENSEECONTACTFORTHISLER{12)50.73(a){2)(v)50.73(a)(2)

{vii)SpecifylnAbstractbeloworinNRCForm366ANAMETELEPHONE NUMBER(IiciudeAreaCode)CarmenVitali-SeniorEngineer(716)771-3606CAUSESYSTEMCOMPONENT MANUFACTURER REPORTABLE TOEPIXIln>.CAUSESYSTEMCOMPONENT MANUFACTURER REPORTABIE TOEPIXSUPPLEMENTAL REPORTEXPECTED(14)YES(Ifyes,completeEXPECTEDSUBMISSION DATE).XNoEXPECTEDSUBMISSION DATE(15)MONTHOAYYEARABSTRACT{Limitto1400spaces,i.e.,approximately 15single-spaced typewritten lines)(16)OnApril12,1999,atapproximately 1600EDST,theplantwasshutdowninMode5.Itwasdiscovered thatthecontainment recirculation fanchevronmoistureseparator vaneswereinstalled backwards, sothatthepathforairflowwaslesstortuous, decreasing moistureseparation effectiveness.

Corrective actionwastoremovethevanesandinstallthemintheproperorientation.

Theincorrect installation wasaresultofimproperassemblybythemanufacturer inthe1960's.Theoriginalmoistureremovalequipment consisted ofanassemblymadeupofthechevrontypevanesandfiberglass moistureremovalpads.Thisequipment wasshop-assembled andshippedtoGinnaStation.Vendorphotographs takenduringoriginalshopassemblyshowthevanesinstalled inamannernowknowntobeincorrect.

Corrective actiontopreventrecurrence isoutlinedinSectionV.99090i0030 990E)24PDRADOCK050002448PDR NRCFORM366A(6.1998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARSEIIUENTIAE NUMBERNUMBER1999-004-01PAGE(3)2OF7TEXTiifmorespaceisrequired, useadditional copiesofhfRCForm366AI(17)PRE-EVENT PLANTCONDITIONS:

OnApril12,1999,theplantwasshutdowninMode5forthe1999refueling outage.Amongthemanyactivities inprogressduringthe1999refueling outage,maintenance wasbeingperformed ontheContainment Recirculation FanCoolers(CRFC)~Atapproximately 1600EDST,anengineerfromNuclearEngineering Services(NES)discovered thatthechevronmoistureseparator vanesfortheCRFCswereinstalled contrarytothatshowninavendormanualdiagram,butcorrectly asshownonavendoroutlinedrawing.DESCRIPTION OFEVENT:A.DATESANDAPPROXIMATE TIMESOFMAJOROCCURRENCES:

oOriginalconstruction circa1969:Eventdateandtime.oApril12,1999,1600EDST:Discovery dateandtime.oApril17,1999,1000EDST:Chevronmoistureseparator vanesarecorrectly installed.

B..EVENT:OnApril12,1999,theplantwasshutdowninMode5forthe1999refueling outage.Amongthemanyactivities inprogressduringthe1999refueling outage,maintenance wasbeingperformed ontheContainment Recirculation FanCoolers(CRFC).Atapproximately 1600EDST,anengineerfromNuclearEngineering Services(NES)discovered thatthechevronmoistureseparator vanesfortheCRFCswereinstalled contrarytothatshownonavendormanualdiagram,butcorrectly asshownonavendoroutlinedrawing.Afterfurtherevaluation anddiscussions withthevendor,itwasconcluded thatthevaneswereinstalled backwards, sothatthepathforairflowislesstortuousthanifthevaneswerecorrectly installed.

ThesevanesareTypeTMistExtractors, manufactured byAmericanAirFilterCo.,Inc.TheCRFCSystemconsistsoffourfanunits(A,B,C,andD),ofwhichtheAandCunitssupplycharcoalfilters.Eachcoolingunitconsistsofamotor,fan,coolingcoils,dampers,moistureseparators (vanesandpads),highefficiency particulate air(HEPA)filters,ductdistributors andnecessary instrumentation andcontrols.

Airisdrawnintothecoolersthroughthefananddischarged intothecontainment atmosphere.

Themoistureseparators functiontoreducethemoisturecontentoftheairstream tosupporttheeffectiveness oftheHEPAandpost-accident charcoalfilters.

NRCFORM366A(61998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMIVIISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)rEANSEGUENTNL NUMUENNUMSEA1999-004-01PAGE(3)3OF7TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366AI(17)Following thecoolingcoilsisthemoistureseparator section,designedtoremoveentrained moistureexitingthecoolingcoils.Twoseparatemoistureremovalprocesses areemployed; thefirstbydirectimpingement onverticalhookedvanes,andthesecondbytrappingonseparator pads.Runofffrombothstagesflowsintocollection pansfromwhichitispipedtothecontainment sump.Themoistureseparator casings,hookedvanes,andcollection pansarefabricated ofgalvanized steel.Withthevanesinstalled backwards, themoistureseparation capability isdecreased.

CRFCperformance wasnotcompletely analyzedforthiscondition.

Thesupplierofthemoistureremovalequipment (American AirFilter)wascontacted.

Itwasconcluded thatthiscondition wasaresultofimproperassemblybythemanufacturer inthe1960's.Theoriginalmoistureremovalequipment consisted ofanassemblymadeupofthechevrontypevanesandfiberglass moistureremovalpads.Thisequipment wasshop-assembled andshippedtoGinnaStation.Vendorphotographs takenduringoriginalshopassemblyshowthevanesinstalled inamannernowknowntobeincorrect.

Asdirectedbythesupplier, thevaneshadtobedismantled andthencorrectly installed.

C.INOPERABLE STRUCTURES, COMPONENTS, ORSYSTEMSTHATCONTRIBUTED TOTHEEVENT:NoneD.OTHERSYSTEMSORSECONDARY FUNCTIONS AFFECTED:

NoneE.METHODOFDISCOVERY:

Thiseventwasdiscovered byanengineerfromNES,whowassupporting CRFCmaintenance.

F.OPERATORACTION:TheplantwasinMode5atthetimeofdiscovery, andtheCRFCsarenotrequiredtobeoperableinthismode.AftertheNESengineernotifiedtheShiftSupervisor ofthiscondition, noimmediate actionswereneededbytheControlRoomoperators.

Subsequently, theShiftSupervisor notifiedhighersupervision andtheNRCGinnaSeniorResidentInspector.

TheShiftSupervisor notifiedtheNRCper10CFR50.72(b)(2)(i),non-emergency fourhournotification, atapproximately 1948EDSTonApril12,1999.G.SAFETYSYSTEMRESPONSES:

None NRCFORM366AISIB98)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAMEI1)R.E.GinnaNuclearPowerPlantDOCKETI2)05000244LERNUMBERIB)TEARSEQUENTIAL REVISIQNNUMBERNUMBER1999-OP4..O1PAGEI3)4OF7TEXTllfmorespaceisrequired, useadditional copiesofNRCForm366'17)III.CAUSEOFEVENT:A.IMMEDIATE CAUSE:Theimmediate causeoftheplantpossiblyoperating outsideitsdesignbasiswasthattheinstalled configuration resultedindecreased moistureseparation capability afteradesignbasisaccident, resulting inlesscoolingcapability.

B.INTERMEDIATE CAUSE'heintermediate causewasinstallation ofimproperly assembled moistureseparator units.Theoriginalmoistureremovalunitsconsisted ofassemblies madeupofthechevrontypevanesandfiberglass moistureremovalpads.Thisequipment wasshop-assembled andshippedtoGinnaStation.Vendorphotographs takenduringoriginalshopassemblyshowthevanesinstalled inamannernowknowntobeincorrect.

C.ROOTCAUSE:Theunderlying causeofthevanesbeinginstalled backwards wasamanufacturing error.IV.ANALYSISOFEVENT:Thiseventisreportable inaccordance with10CFR50.73,LicenseeEventReportSystem,item(a)(2)(ii)(B),whichrequiresareportof,"Anyeventorcondition thatresultedinthecondition ofthenuclearpowerplant,including itsprincipal safetybarriers, beingseriously degraded; orthatresultedinthenuclearpowerplantbeing:(B)Inacondition thatisoutsidethedesignbasisoftheplant.Anassessment wasperformed considering boththesafetyconsequences andimplications ofthiseventwiththefollowing resultsandconclusions:

Therewerenooperational orsafetyconsequences orimplications attributed tothemoistureseparator vanesinstalled backwards because:Themaximumairvelocitythroughthecontainment recirculation fancoolingcoilsafteraloss-of-coolantaccident(LOCA)airvelocitythroughthecoilisbelowtheAmerican'Society ofHeating,Refrigerating andAir-Conditioning Engineers (ASHRAE)threshold of600feetperminute(FPM)formoistureentrainment bothforthenewandoldconfiguration.

Thecoilswillactasmoistureseparators duetothedepthofthecoilandspacingbetweenfins,eveniftheyarenotoperating

.Aheatingcoilsimilartothecoolingcoilsinstalled atGinna,wastestedwithaspraystreamequivalent totheGinnaStationLOCAenvironment directedatthecoilentrance, butwithaslightlylowerairstreamvelocity(400FPM)thanGinna.Nomoisturecarry-over wasobservedontheoutletofthecoiloronthemoistureseparator downstream ofthecoil.Approximately 5%ofthespraywasevaporated bythecoilheating.

NRCFORM366A(91998)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)"TEARSEOUENTIAL REUISIONNUMBERNUMBER1999-004-01PAGE(3)6OF7TEXTIifmorespaceisrequired, useadditionalcopiesofNRCForm366AI(17)Additional louversarelocatedontheinlettothecoilswhichwillremovesomeentrained moisturepriortoenteringthecoolingcoils,whicharenottakencreditforintheCRFCunitoperation.

Theairvelocitysignificantly reducesafterexitfromthecoolingcoils,andwouldallowentrained dropletstofalltothefanunitfloorpriortoreachingtheHEPAfilterswhicharelocatedapproximately 6feetfromthecoolingcoils.0Themoistureseparator mediapadslocatedupstreamoftheHEPAfiltershavebeentestedandfoundtoremovemoistureupto1.5Ibs/100cu.ft.Themaximumexpectedentrained moisturecontentinthecontainment environment duetocontainment sprayandcondensation isonlyOAIbs/1000cu.ft.Theoriginalmediapadsinstalled atGinna(American AirFilterModelM-105)werereplacedwithnewmodelM-81padsthathavenotbeentestedtoGinnaLOCAconditions.

However,duetosimilarities indesign,theyareexpectedtoremainfunctional eventhoughtheyhavenotbeencreditedtofunctionduetolackofqualification.

Themoistureseparator vanesontheoutletofthecoilwouldstillremoveentrained watereventhoughtheyareinstalled backwards, duetotheirtortuouspath.Thenumberofhookswhichprotrudeintotheflowstreamisreducedfrom3to1.However,themoistureremovalisdominated bythespacingbetweenadjacentvanes,lengthofeachvaneandnumberofvaneturnsinpath,allofwhichareunaffected withthevanesinstalled backwards.

Thewaterdropsfollowasine-wave paththroughthevanes.Theoverallefficiency forthebackwards installation isestimated tobe25%.Themoistureremovalcapacityrequirement asspecified intheoriginalBillofMaterials forthemoistureremovalsectionoftheCRFCunitis0.4Ibs/1000cu.ft.This25%reduction inthevaneefficiency canbeeasilycompensated forbythemoistureremovalpadssincetheyweretestedatmoisturelevelsofgreaterthan1.0Ibs/1000cu.ft.Inaddition, theHEPAfilterswerealsotestedandtheirpressuredropincreased by0.5incheswithanequivalent moistureloadingofOAIbs/1000cu.ft.Itisbelievedthattheadditional 0.5inchesofpressurelossiswithintheexistingmarginoftheas-installed equipment andwouldresultinreduction intotalsystemCRFCflowoflessthan10%0ThemainimpactofaslightlyreducedCRFCcoolingcapability onthedesignbasisaccidents (DBAs)suchasLOCAsandMainSteamLineBreaks(MSLBs)wouldbeareduction inthelongtermcoolinganddepressurization capability ofcontainment.

Impactonpeakcontainment pressures forDBAsisexpectedtobenegligible.

Sincepeakcontainment pressures typically occurwithinthefirstcoupleofminutesfollowing DBAs,theincreaseinHEPAfilterhydraulic resistance wouldnotbefullydeveloped overthistimeduetothelimitedwaterloadingontheHEPAfiltersimmediately following aDBA.Additionally, theearlyoccurrence ofcontainment peakpressures limitstheintegrated amountofenergythatisremovedbytheCRFCsuptothetimeofpeakcontainment pressure.

Therefore, anydegradation inCRFCheatremovalcapability duetoreducedairsideflowimmediately following aDBAwouldhaveanegligible impactontheoverallcontainment energybalanceatthetimeofpeakcontainment pressure.

Baseduponthesefactors,anyincreaseinpeakcontainment pressurethatcouldhaveoccurredasaresultoftheimproperly installed louversisjudgedtobewithintheoverallstructural capability ofthecontainment following aDBA,althoughcontainment designpressuremayhavebeenslightlyexceeded.

r NRCFORM366A(61968)LlCENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARBEOUENTNL NUMBERNUN'IBER1999-004-01PAGE(3)6OF7TEXTIlfmorespaceisrequired, useadditional copiesofNRCForm366AI(17)Aspreviously stated,themajorimpactofreducedheatremovalcapability duetowaterloadingoftheHEPAfilterswouldbeonlongtermcontainment cooling,sinceContainment Sprayflowisterminated aftertheplanthastransitioned totheRecirculation Modeofcooling.Anyreduction inCRFCcoolingcapability duetoreducedairflowwouldcauseaslowercontainment coodownanddepressurization.

Althoughthisslowercontainment cooldowncouldpotentially affecttheEquipment Qualification (EQ)profilesofsafety-related equipment incontainment, areviewoftheexistingGinnaEQprofilesforcontainment indicates thatsufficient marginexistsduringthefirsttwenty-four hoursfollowing aDBAtoaccommodate aslowercooldown.

Consequently, noadverseimpactonpastoperability ofqualified equipment incontainment isexpectedtohaveexisted.oTheGinnaControlRoomandoff-sitedosecalculations werere-evaluated assumingactualcontainment integrated leakagefromtestingperformed in1996andactualpredicted containment depressurization ratesforGinna.Basedontheseassumptions andcontinuous operation oftheCRFCsinapost-LOCA environment, itisestimated thataminimumcharcoalfilteriodineremovalefficiency of10%wouldberequiredtomaintainoff-sitedosesbelow300RemandControlRoomthyroiddosesbelow30RemandtherebysatisfytheGinnalicensing basisrequirement asrequiredby10CFR100andGeneralDesignCriterion (GDC)19.Basedonadditional analysisthatwasperformed byRG(ltEin1999,charcoalfilterswerefoundtohave40%oftheirvolumestillavailable foriodineremovalevenwhen100%saturated.

Sincetheminimumrequiredcharcoaliodineremovalefficiency isappreciably smallerthantheminimumexpectedcharcoalefficiency of40%forawettedcondition, thedesignfunctionofthefiltersasitrelatestothyroidsdosetoon-siteandoff-sitepersonnel wouldstillhavebeensatisfied evenwiththelouversinstalled backwards.

Basedontheaboveandthereviewofpastplanttransients, itcanbeconcluded thatthepublic'shealthandsafetywasassuredatalltimes.V.CORRECTIVE ACTION:A.ACTIONTAKENTORETURNAFFECTEDSYSTEMSTOPRE-EVENT NORMALSTATUS:Themoistureseparator vanesweredismantled andcorrectly re-installed.

B.ACTIONTAKENORPLANNEDTOPREVENTRECURRENCE:

Theas-leftconfiguration ofthemoistureseparator unitsdoesnotallowthevanestobeinstalled incorrectly.

VI.ADDITIONAL INFORMATION:

A.FAILEDCOMPONENTS:

None

NRCFORM366A(6.1898)LICENSEEEVENTREPORT(LER)TEXTCONTINUATION U.S.NUCLEARREGULATORY COMMISSION FACILITYNAME(1)R.E.GinnaNuclearPowerPlantDOCKET(2)05000244LERNUMBER(6)yEARSEOUENTIAE REVISIONNUMBERNUMBER1999-004-01PAGE(3)7OF7TEXT(Ifmorespaceisrequired, useadditional copiesofNRCForm366AJ(17)B.PREVIOUSLERsONSIMILAREVENTS:AsimilarLEReventhistorical searchwasconducted withthefollowing results:Nodocumentation ofsimilarLEReventswiththesamerootcauseatGinnaStationcouldbeidentified.

C.SPECIALCOMMENTS:

None