IR 05000333/2022010
| ML22178A137 | |
| Person / Time | |
|---|---|
| Site: | FitzPatrick  |
| Issue date: | 06/27/2022 |
| From: | Mel Gray Division of Operating Reactors |
| To: | Rhoades D Constellation Energy Generation, Constellation Nuclear |
| Gray M | |
| References | |
| IR 2022-010 | |
| Download: ML22178A137 (16) | |
Text
June 27, 2022
SUBJECT:
JAMES A. FITZPATRICK NUCLEAR POWER PLANT - REISSUED DESIGN BASIS ASSURANCE INSPECTION (TEAMS) INSPECTION REPORT 05000333/2022010
Dear Mr. Rhoades:
The U.S. Nuclear Regulatory Commission (NRC) identified one factual error in Design Basis Assurance Inspection (Teams) Inspection Report 05000333/2022010, dated June 2, 2022 (ADAMS Accession No. ML22153A261). The cover letter and report cover page listed the inspection end date as May 20, 2022, whereas the inspection ended on May 19, 2022. As a result, the NRC has reissued the report in its entirety to correct the error.
This letter, its enclosure, and your response (if any) will be made available for public inspection and copying at http://www.nrc.gov/reading-rm/adams.html and at the NRC Public Document Room in accordance with Title 10 of the Code of Federal Regulations 2.390, Public Inspections, Exemptions, Requests for Withholding.
Sincerely, Digitally signed by Melvin K. Gray Melvin K. Gray Date: 2022.06.27 14:58:33-04'00'
Mel Gray, Chief Engineering Branch 1 Division of Operating Reactor Safety Docket No. 05000333 License No. DPR-59
Enclosure:
As stated
Inspection Report
Docket Number: 05000333 License Number: DPR-59 Report Number: 05000333/2022010 Enterprise Identifier: I-2022-010-0045 Licensee: Constellation Energy Generation, LLC Facility: James A. FitzPatrick Nuclear Power Plant Location: Scriba, NY Inspection Dates: May 2, 2022 to May 19, 2022 Inspectors: C. Bickett, Senior Reactor Inspector J. Brand, Reactor Inspector P. Cataldo, Senior Reactor Inspector E. Dipaolo, Senior Reactor Inspector E. Eve, Senior Reactor Inspector J. Schoppy, Senior Reactor Inspector Approved By: Mel Gray, Chief Engineering Branch 1 Division of Operating Reactor Safety Enclosure
SUMMARY
The U.S. Nuclear Regulatory Commission (NRC) continued monitoring the licensees performance by conducting a design basis assurance inspection (teams) inspection at James A.
FitzPatrick Nuclear Power Plant, in accordance with the Reactor Oversight Process. The Reactor Oversight Process is the NRCs program for overseeing the safe operation of commercial nuclear power reactors. Refer to https://www.nrc.gov/reactors/operating/oversight.html for more information.
List of Findings and Violations
Inadequate Test Control for Modified Performance Discharge Testing of 'B' Station Battery Cornerstone Significance Cross-Cutting Report Aspect Section Mitigating Green [H.8] - 71111.21M Systems NCV 05000333/2022010-01 Procedure Open/Closed Adherence The team identified a Green non-cited violation (NCV) of 10 CFR Part 50, Appendix B,
Criterion XI, Test Control, because Constellation personnel did not perform battery testing in accordance with written test procedures. Specifically, the test deficiencies included: 1) the initial battery terminal voltage did not meet the test prerequisite; 2) technicians did not ensure that an adequate and reliable power supply was available for test equipment as required in the test prerequisites which resulted in a pause in testing; 3) the duration of the pause in testing was inappropriately included in the total duration of the battery discharge; and 4)records of individual cell voltages and battery terminal voltages required to be read and recorded at various stages of the test were not included in the official test record.
Additional Tracking Items
None.
INSPECTION SCOPES
Inspections were conducted using the appropriate portions of the inspection procedures (IPs) in effect at the beginning of the inspection unless otherwise noted. Currently approved IPs with their attached revision histories are located on the public website at http://www.nrc.gov/reading-rm/doc-collections/insp-manual/inspection-procedure/index.html. Samples were declared complete when the IP requirements most appropriate to the inspection activity were met consistent with Inspection Manual Chapter (IMC) 2515, Light-Water Reactor Inspection Program - Operations Phase. The inspectors reviewed selected procedures and records, observed activities, and interviewed personnel to assess licensee performance and compliance with Commission rules and regulations, license conditions, site procedures, and standards.
REACTOR SAFETY
===71111.21M - Design Bases Assurance Inspection (Teams) The inspectors evaluated the following components and listed applicable attributes, permanent modifications, and operating experience:
Design Review - Risk-Significant/Low Design Margin Components (IP Section 02.02)
=
The team evaluated the following components, permanent modifications, and operating experience during the weeks of May 2 and May 16, 2022.
For the components, the team reviewed the attributes listed in IP 71111.21M, Appendix A, Component Review Attributes, such as those listed below. Specifically, the team evaluated these attributes as per IP 71111.21M, Appendix B, Component Design Review Considerations and 71111.21M, Appendix C, Component Walkdown Considerations. Specific documents reviewed are listed in the Documents Reviewed section.
- (1) Loss of AC Bus 10500 Initiating Event
- Material condition and installed configuration (e.g., visual inspection/walkdown)
- Normal, abnormal, and emergency operating procedures
- Consistency among design and licensing bases and other documents/procedures
- Maintenance records and corrective action history
- Adequacy of design (calculations and modifications)
- Surveillance testing and test results
- System and component level performance monitoring
- Equipment protection from fire, flood, water intrusion, or spray
- Heat removal, cooling water and ventilation
- Control logic
- Component adequacy for minimum voltage
- Protection coordination (load in-rush and full load current)
- Range, accuracy, and setpoint of installed instrumentation
- Operator actions
- Process medium availability (water, air, electrical signal)
- Energy source availability (electricity, steam, fuel, air)
The team used Appendix B guidance for Instrumentation, Circuit Breakers and Fuses, Cables, Electrical Loads, and Motor Control Centers (MCCs).
- (2) High Pressure Coolant Injection System (Failure to Run)
- Material condition and installed configuration (e.g., visual inspection/walkdown)
- Normal, abnormal, and emergency operating procedures
- Consistency among design and licensing bases and other documents/procedures
- System health report, maintenance records, and corrective action history
- Surveillance testing and test results
- System and component level performance monitoring
- Control logic
- Operator actions
- Process medium availability (water, air, electrical signal)
- Energy source availability (electricity, steam, fuel, air)
The team used Appendix B guidance for Valves, Pumps, Instrumentation, and As-Built System.
- (3) Containment Venting (Loss of Function)
- Material condition and installed configuration (e.g., visual inspection/walkdown)
- Normal, abnormal, and emergency operating procedures
- Consistency among design and licensing bases and other documents/procedures
- System health report, maintenance records, and corrective action history
- Equipment/environmental controls and qualification
- Adequacy of design (calculations and modifications)
- Surveillance testing and test results
- System and component level performance monitoring
- Equipment protection from fire, flood, steam, water intrusion, or spray
- Heat removal, cooling water and ventilation
- Control logic
- Range, accuracy, and setpoint of installed instrumentation
- Operator actions
- Process medium availability (water, air, electrical signal)
- Energy source availability (electricity, steam, fuel, air)
The team used Appendix B guidance for Valves, Pumps, Instrumentation, and As-Built System.
- (4) B 125 Vdc Battery (SB-2) and Battery B Control Board (BCB-2B)
- Material condition and installed configuration (e.g., visual inspection/walkdown)
- Normal, abnormal, and emergency operating procedures
- Consistency among design and licensing bases and other documents/procedures
- Maintenance records and corrective action history
- Equipment/environmental controls and qualification
- Adequacy of design (calculations and modifications)
- Surveillance testing and test results
- System and component level performance monitoring
- Equipment protection from fire, flood, steam, water intrusion, or spray
- Ventilation for temperature control and hydrogen removal
- Circuit breaker and fuse ratings
- Component adequacy for minimum voltage
- Protection coordination (load in-rush, full load current, and short-circuit protection)
- Range, accuracy, and setpoint of installed instrumentation
- Operator actions
- Energy source availability (charger availability, capability, and reliability)
The team used Appendix B guidance for Instrumentation, Circuit Breakers and Fuses, Cables, Electric Loads, and Motor Control Centers (MCCs).
Design Review - Large Early Release Frequency (LERFs) (IP Section 02.02) (1 Sample)
- (1) B Loop Suppression Pool Cooling and Containment Spray (Loss of Function)
- Material condition and installed configuration (e.g., visual inspection/walkdown)
- Normal, abnormal, and emergency operating procedures
- Consistency among design and licensing bases and other documents/procedures
- System health report, maintenance records, and corrective action history
- Equipment/environmental controls and qualification
- Adequacy of design (calculations and modifications)
- Surveillance testing and test results
- System and component level performance monitoring
- Equipment protection from fire, flood, steam, water intrusion, or spray
- Heat removal, cooling water and ventilation
- Control logic
- Range, accuracy, and setpoint of installed instrumentation
- Operator actions
- Process medium availability (water, air, electrical signal)
- Energy source availability (electricity, steam, fuel, air)
The team used Appendix B guidance for Valves, Pumps, Instrumentation, and As-
===Built System.
Modification Review - Permanent Mods (IP Section 02.03) (5 Samples)===
- (3) EC 628065, 72MOD-101B(OP) Replacement with New Model Operator
Piston Check Review of Operating Experience Issues (IP Section 02.06) (2 Samples)
- (1) NRC Information Notice 2019-01: Inadequate Evaluation of Temporary Alterations
- (2) NRC Information Notice 2020-02: FLEX Diesel Generator Operational Challenges; Operating Experience Smart Sample (OpESS) 2020/01 was used to inform the inspection sample
INSPECTION RESULTS
Inadequate Test Control for Modified Performance Discharge Testing of 'B' Station Battery Cornerstone Significance Cross-Cutting Report Aspect Section Mitigating Green [H.8] - 71111.21M Systems NCV 05000333/2022010-01 Procedure Open/Closed Adherence The team identified a Green non-cited violation (NCV) of 10 CFR Part 50, Appendix B, Criterion XI, Test Control, because Constellation personnel did not perform battery testing in accordance with written test procedures. Specifically, the test deficiencies included: 1) the initial battery terminal voltage did not meet the test prerequisite; 2) technicians did not ensure that an adequate and reliable power supply was available for test equipment as required in the test prerequisites which resulted in a pause in testing; 3) the duration of the pause in testing was inappropriately included in the total duration of the battery discharge; and 4)records of individual cell voltages and battery terminal voltages required to be read and recorded at various stages of the test were not included in the official test record.
Description:
Constellation completed a battery modified performance discharge test on the B 125V DC station service battery (71SB-2) on September 18, 2020, to satisfy Technical Specification (TS) Surveillance Requirement (SR) 3.8.4.3, to verify adequate battery capacity to support emergency loads, and TS SR 3.8.4.4, to verify battery capacity was > 80 percent of the manufacturers rating. Per the TS SR 3.8.4.4 Bases, the acceptance criteria for battery testing are consistent with Institute of Electrical and Electronics Engineers Standard 450, IEEE Recommended Practice for Maintenance, Testing, and Replacement of Vented Lead-Acid Batteries for Stationary Applications, 1995 (IEEE 450).
The team reviewed the documentation for the battery modified performance discharge test performed in accordance with Constellation procedure MST-071.24, Station Battery B Modified Performance Test, Revision 19. The team identified several instances where the test procedure was not followed and/or the problem was not entered into the corrective action program.
First, the battery terminal voltage before starting the test did not meet the test prerequisite.
MST-071.24, Prerequisite Step 8.13 required that the battery be on a float charge with battery terminal voltage between 131 - 133V DC. Actual voltage was 136V DC due to the battery being charged by the swing charger and technicians believed the swing charger voltage could not be adjusted to the required range. This was discussed with the on-shift senior reactor operator and the decision made to continue with the test. The actual voltage of 136V DC was within the equalizing charge range. IEEE 450 specifies that the battery be on a float charge for a minimum of 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> following being on an equalizing charge prior to starting the discharge test.
Second, technicians did not ensure that adequate and reliable power was available for test equipment as stated in the test prerequisites. MST-071.24, Prerequisite Step 8.11 required technicians to Ensure an AC outlet (nominal 120 VAC, 20 Amp) is available for test equipment and other outlets on circuit are not used during test except to power test equipment. Tag other outlets as necessary. The purpose of this step was to ensure a reliable control power source to the battery test equipment during the performance of the test.
Constellation personnel did not adequately perform this step. As a result, at approximately 16 minutes into the test, the power supply was lost to the test equipment. This resulted in an 11.53 minute pause in testing. IEEE 450 only provides for one short duration pause in testing (10 percent of the test duration or 6 minutes, whichever is shorter) for the specific purpose of disconnecting a battery cell that is approaching reversal of polarity early in the test. Test data showed that battery terminal voltage was higher when the load was reapplied than prior to the pause in testing. This demonstrated that the battery recovered during the pause and that the battery test would indicate a higher battery capacity than if no pause occurred. The team noted that technicians did not initiate a corrective action issue report (IR) for this problem encountered during the testing.
Third, the 11.53 minute duration of the pause in testing was inappropriately included in the total duration of the battery discharge. This resulted in a higher and non-conservative calculated battery capacity versus actual capacity.
Fourth, records of individual cell voltages and battery terminal voltages required to be read and recorded at the beginning of the test, at specified intervals, and at the completion of the test per the guidance contained in IEEE 450 were not included in the official test record.
Specifically, personnel did not comply with Step 10.7 which stated to Obtain a printout of the individual cell voltages from the Alber BCT 2000 test equipment and include in work package.
Corrective Actions: Constellations short-term corrective actions included performing a technical evaluation (EC 636754) to assess battery operability and capacity of the B 125V DC station service battery and entering the issues into their corrective action program.
Factoring in the pause in the testing and other considerations, Constellation staff determined that the worst-case battery capacity was 101.08 percent (as compared to the battery capacity of 106.8 percent recorded following the test in September 2020). This demonstrated that the battery had margin to the TS required > 80 percent capacity and that the battery did not show signs of degradation (i.e., capacity was not greater than 10 percent lower than the previous modified performance discharge test).
Corrective Action References: IRs 4497226, 4497328, 4497663, and 4497832.
Performance Assessment:
Performance Deficiency: The licensee failed to conduct modified performance discharge testing on the B 125V DC station service battery (71SB-2) on September 18, 2020, in accordance with written test procedures consistent with the recommendations and acceptance criteria contained in IEEE 450. Specifically, the test was started with battery terminal voltage in the equalize range, technicians did not ensure that an adequate and reliable power supply was available for test equipment as required in the test prerequisites which resulted in a pause in testing, the duration of the pause in testing was inappropriately included in the total duration of the battery discharge, and records of individual cell voltages and battery terminal voltages were not included in the official test record.
Significance: The inspectors assessed the significance of the finding using Appendix A, The Significance Determination Process (SDP) for Findings At-Power. Though the performance deficiency occurred while the plant was shut down, the assessment of risk was best represented by using Appendix A, The Significance Determination Process (SDP) for Findings At-Power, using Exhibit 2, Mitigating Systems Screening Questions, of IMC 0609, Appendix A. The team determined that this finding was a deficiency affecting the design or qualification of mitigating structures, systems, or components, where the structures, systems, or components maintained their operability or functionality. Although not performed consistent with the acceptance criteria of IEEE 450, the test did demonstrate with reasonable confidence that there was sufficient margin to the TS required battery capacity of > 80 percent. Therefore, the team determined the finding to be of very low safety significance (Green).
Cross-Cutting Aspect: H.8 - Procedure Adherence: Individuals follow processes, procedures, and work instructions. Specifically, Constellation personnel did not follow the modified performance discharge test procedure when performing the test on the B 125V DC station service battery on September 18, 2020.
Enforcement:
Violation: 10 CFR 50, Appendix B, Criterion XI, Test Control, requires, in part, that a test program shall be established to assure that all testing required to demonstrate that structures, systems, and components will perform satisfactorily in service is identified and performed in accordance with written test procedures which incorporate the requirements and acceptance limits contained in applicable design documents. Constellation was committed to perform battery modified performance discharge testing consistent with the recommendations and acceptance criteria of IEEE 450 and required to perform battery modified performance discharge testing of the B 125V DC station service battery in accordance with MST-071.24, Station Battery B Modified Performance Test, Revision 19.
Contrary to the above, on September 18, 2020, Constellation personnel did not perform battery modified performance discharge testing on the B 125V DC station service battery (71SB-2) in accordance with written test procedures consistent with the recommendations and acceptance criteria contained in IEEE 450. Specifically, the test deficiencies included: 1)the initial battery terminal voltage did not meet the test prerequisite (required range 131-133V DC versus actual 136V DC and was in the equalizing charge range which was not consistent with IEEE 450); 2) technicians did not ensure that adequate and reliable power was available for test equipment as stated in the test prerequisites (the loss of power to test equipment during the test resulted in an 11.53-minute test interruption which was not consistent with IEEE 450); 3) including the 11.53 minute duration of the pause in testing from the total duration of the battery discharge resulted in a higher and non-conservative calculated battery capacity versus actual capacity; and 4) records of individual cell voltages and battery terminal voltages required to be read and recorded at the beginning of the test, at specified intervals, and at the completion of the test per IEEE 450 guidance were not included in the official test record. Because this violation was of very low safety significance (Green) and has been entered into Constellations corrective action program, the NRC is treating this violation as a Non-Cited Violation (NCV), consistent with Section 2.3.2.a of the NRC Enforcement Policy.
(NCV 05000333/20220010-01, Inadequate Test Control for Modified Performance Discharge Testing of B Station Battery)
Enforcement Action: This violation is being treated as a non-cited violation, consistent with Section 2.3.2 of the Enforcement Policy.
EXIT MEETINGS AND DEBRIEFS
The inspectors verified no proprietary information was retained or documented in this report.
- On May 19, 2022, the inspectors presented the design basis assurance inspection (teams) inspection results to Mr. Timothy Peter, Site Vice President, and other members of the licensee staff.
DOCUMENTS REVIEWED
Inspection Type Designation Description or Title Revision or
Procedure Date
71111.21M Calculations JAF-CALC-15- FLEX Strategy - Portable Generator System Sizing Revision 0
00031
JAF-CALC-CAD- Design Basis Calculations for the Torus Inner and Outer Revision 0
04481 Exhaust AOVs 27AOV-117 & 27AOV-118 at FitzPatrick NPP
JAF-CALC- 125V DC System Short-Circuit Calculation and Coordination Revision 1
ELEC-02016 Evaluation
JAF-CALC- Determination of Float and Equalize Voltage for Station Revision 1
ELEC-02551 Batteries 71SB-1 & 71SB2
JAF-CALC-SWS- Local Wall Thinning Evaluation for ESW Strainers 46STR- Revision 2C
04170 5A/B
Corrective Action 04036374
Documents 04176609
221269
246355
252619
252625
266619
290349
04319445
04323766
04335008
04339876
04347868
04348143
04369686
04371604
04371715
04372411
04372680
04373277
04374549
04377286
Inspection Type Designation Description or Title Revision or
Procedure Date
04381156
04384096
04384807
04385340
04389930
04394054
04401931
04407061
04425606
04425805
04428931
04455782
04467798
04483344
04483639
04483997
04496433
04496616
04497610
CR-JAF-2007-
03363
Corrective Action 04497169
Documents 04497226
Resulting from 04497328
Inspection 04497349
04497394
04497395
04497409
04497663
04497664
04497672
04497680
04497832
04497910
Inspection Type Designation Description or Title Revision or
Procedure Date
04497962
04497964
04497965
04497967
04497969
04497970
04497997
04498019
04498006
04498022
04498129
04498210
04499080
04500102
04500121
04500293
04500320
04500330
04500418
04500553
04500554
04500555
04500563
04500635
04500821
Drawings FE-1H Sh. 4 4160V One Line Diagram Emergency Bus 10500 Revision 14
FM-20A Residual Heat Removal System Flow Diagram Revision 73
FM-25A High Pressure Coolant Injection Flow Diagram Revision 75
Miscellaneous DBD-023 Design Basis Document for the High Pressure Coolant Revision 12
Injection System
E406-0001 200 KW FLEX Diesel Generator Revision 1
G185-0029 Instruction Manuals for 60 Cells NCN-33 or NCN-35 (GNB dated
Industrial Power) 9/11/11
JAF-SPEC-MISC- James A. FitzPatrick Nuclear Power Plant Piping Revision 15
Inspection Type Designation Description or Title Revision or
Procedure Date
00334 Specification
NRC Information Battery and Battery Charger Short-Circuit Current dated
Notice 2017-06 Contributions to a Fault on the Direct Current Distribution 9/26/17
System
OP-AA-102-106, Operator Response Time Validation Sheet performed
Att. 1 11/12/20
P319-0047 Three-Phase Magnetic Amplifier Controlled CP Battery Revision 8
Charger
RHR 2B 10E-2B Preliminary Report of Eddy Current Inspections dated
11/20/13
SDLP-23 High Pressure Coolant Injection System Revision 28
ST-1CA Outside Primary Containment Isolation Valve Exercise Test performed
(IST) 3/16/22
ST-2AK RHR Loop B Containment Spray Headers and Nozzles Air performed
Test (ISI) 9/23/12
ST-2AM RHR Loop B Quarterly Operability Test (IST) performed
3/10/21 &
3/8/22
Procedures AOP-18 Loss of 10500 Bus Revision 18
AOP-19 Loss of 10600 Bus Revision 18
CC-JF-118 Site Implementation of Diverse and Flexible Coping Revision 5
Strategies (FLEX) and Spent Fuel Instrumentation Program
EP-6 Post Accident Containment Venting and Gas Control Revision 13
OP-13 Residual Heat Removal System Revision 100
OP-15 High Pressure Coolant Injection Revision 69
Work Orders 00205886
00340684
04655870
04806288
04806289
04915450
04938333
04938334
04938915
Inspection Type Designation Description or Title Revision or
Procedure Date
04943427
04964506
05043091
05047158
05131958
05131959
05150464
05150801
2606584
2705256
2740044
99-01814-00
14