IR 05000412/1986018

Insp Rept 50-412/86-18 on 860707-11.No Noncompliance Noted. Major Areas Inspected:Preoperational Test Program,Including Joint Test Group Preoperational Test Procedures & Test Results for RCS Cold Hydrostatic Test

ML20205B048
Person / Time
Site:	Beaver Valley
Issue date:	08/01/1986
From:	Eselgroth P, Joe Golla, Van Kessel H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20205B016	List: IR 05000412/1986018 ML20205B011
References
50-412-86-18, NUDOCS 8608110510
Download: ML20205B048 (11)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION I

Report No. 50-412/86-18 Docket N License N CPPR-105 Category B Licensee: Duquesne Light Company Post Office Box 4 Shippingport, Pennsylvania 15077 Facility Name: Beaver Valley Power Station, Unit No. 2 Inspection At: Shippingport, Pennsylvania Inspection Conducted: July 7-11, 1986 Inspectors: ~

H. F. van Kessel, Reactor Engineer date ?

alla, RVactor Engineer 7- 3 / -6'&

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P. W. Eselg h, Chief, Test Programs 8-b 8d date Section, erations Branch, DRS Inspection Summary: Inspection on July 7-11, 1986 (Inspection N /86-18)

Areas Inspected: Routine Unannounced inspection of the Preoperational Test Program, including the review of approved Joint Test Group (JTG) preoperational test procedures and conditionally approved JTG test results for the RCS Cold Hydrostatic test, review of the activities in the QA/QC interface area and the review of unresolved items identified by the inspector in previous inspection An independent review was made of the phase-1 test results for manual and motor operated valves and for the SFP Bridge Hoists and platfor Results: No items of noncompliance were identifie NOTE: For Acronyms not defined refer to NUREG-0544, " Handbook of Acronyms and Initialisms" 860s11051o e60905 2 PDR ADOCK 0500

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. Persons Contacted Duquesne Light Company (DLC)

• R. C. Callaway, Supervisor Startup Testing

• N. J. Daugherty, Systems Test Director J. J. Johns, Supervisor QA Surveillance

• T. P. Noonan, Superintendent Operations and Maintenance J. S. Patterson, Startup Engineer M. Pavlick, Director Support Services

• L. M. Rabenau, Compliance Engineer S. Smajda, Director SOV Testing

• R. J. Swiderski, Startup Manager L. P. Williams, Director Startup

• R. G. Williams, Supervisor System Test Software De U.S. Nuclear Regulatory Commission W. Troskosky, Senior Resident Inspector J. A. Golla, Reactor Engineer

• Denotes those present at exit interview on July 11, 198 .0 Licensee Action on Previous Inspection Findings (Closed) Unresolved Item 412/85-08-01, " Classification of tests for the Preoperational Test Program" Scope A review of the classification of preoperational tests concerns the identification of these tests for performance in the correct time frame relative to the milestones of the startup program, i.e., Cold Hydro, Fuel Loading, Initial Criticality, Start of Low Power Testing, and start of Power Escalatio References (1) Milestone schedule printout of preoperational test schedule for Beaver Valley 2, received on July 8, 1986 (2) Duquesne Light Co. Memorandum from R. J. Swiderski to distribution,

" Recovery Schedule Target Dates", dated June 18, 1986 (3) Inspection Report 50-412/86-11 Discussion An up-to-date listing of the preoperational test procedures was obtained from the licensee. This listing has been cross referenced with the FSAR listing, the descriptions in Appendix A of Regulatory Guide 1.68, and the

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Discussion An up-to-date listing of the preoperational test procedures was obtained from the licensee. This listing has been cross referenced with the FSAR listing, the descriptions in Appendix A of Regulatory Guide 1.68, and the preoperational test schedule as defined recently by the . licensee. The in-spector has completed this review. Essentially all of the preoperational tests for fluid systems are planned for completion prior to Fuel Loadin Any retesting will be accomplished after Fuel Loading but before Initial Criticality. At this point there are no plans or procedures for a Post Core Load Hot Functional Test. Retests for test exceptions incurred during the Hot Functional Test (HFT), however, will be performed under HFT Condi-tions after Core Load.

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The schedule shown in reference 2 confirms that all preoperational tests for primary fluid systems (except HVAC) are planned for completion prior to core loadin The inspector has no further questions on this subject at this tim Findings This unresolved item is close .0 Preoperational Test (POT) Program 3.1 Test Procedure Review Scope The test procedures listed in Attachment A were reviewed for adminis-

'i trative and, selectively, for technical adequacy and to verify that test planning satisfies regulatory guidance and licensee commitment I Discussion The procedures were examined for the attributes listed in Inspecticn I Report 50-412/86-1 No problems or discrepancies were encountere Findings

No violations or noncompliances were identified by the inspecto i 3.2 Test Result Evaluation Scope The test report for procedure P0.2.06.01, " Cold Hydrostatic Test of the RCS" was reviewed to verify that adequate testing was accomplished in

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order to satisfy regulatory guidance and licensee commitments and to ascertain completed preoperational tests in order to assure their technical and administrative adequac Discussion The test results were reviewed for the attributes listed in Inspection Report 50-412/86-11, Section 3. The test report has been approved conditionally by the Joint Test Group (JTG).

Certain restorational steps still have to be completed before final approval can be given. Although the test was successful, certain problems were encountered with the required recording of the test data during the test. These deviations from the requirements contained in the Startup Manual (SUM) were identified by the QA Unit. These test deficiencies are discussed in more detail under Section 5 of this repor All of the test deficiencies on record in the report carry an entry date of May 15, 1986 which is after the test completion dat It was noted that the original recorder charts for the metal tempera-tures (from temporary thermocouples) had not been added to the test file for safekeeping as part of the official record. The data from these charts are plotted on a separate graph for the test repor This is Unresolved Item 86-18-0 Individual Test Deficiency forms were not required at the time of the test. Only a Test Deficiency Record was required to be produced dur-ing the tes The SUM was revised recently to incorporate the indivi-dual test deficiency sheets. A Test Deficiency Record was produced

.for the first three items (out of 5) during the test in April of this year. The last two items are dated after the tes The resolution of all 5 test deficiencies will be followed under Unresolved Item 86-18-0 Findings No violations were identified by the inspecto . Independent Inspection Effort Scope Review the phase-1 test results for manual and motor operated safety related valves to determine what major generic problems, including valve position indication problems, have been encountered. Also review the results for the hoists and cranes of the Fuel Handling System for generic control circuit problem References Refer to Attachment B

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Discussion The references listed in Attachment B were reviewed to obtain an overall impression of the type of problems encountered for the equipment categories, mentioned in the scope above, during the phase-1 testing, which basically is construction verification testing. The references include a number of test deficiency reports (TDRs) for the manual and motor operated valve While these TDRs indicate a number of valve problems, there does not appear to be a generic trend. Valve position indication components did not appear as a problem in any of the TDRs of the samples listed in Attachment The only crane which appears to have completed phase-1 testing is the New Fuel and Spent Fuel Crane (ref. 23). While some problems were discovered during the phase-1 testing, these problems were corrected and retests show that the crane is operabl Findings No violations were identifie .0 QA/QC Interface Scope The participation of the Duquesne Light QA Surveillance Group in the pre-operational test program was evaluated by the inspector. Of particular interest were the surveillances performed by this group during the recently performed Cold Hydrostatic test of the RC Discussion A number of the test deficiencies, identified by the DLC QA Surveillance Group and listed in Attachment B of Inspection Report 50-412/86-11, had received responses from management. The response ccrrespondence is refer-enced in Attachment C (ref. I and 2) References 1 and 2 address deficiencies No. 2 and 3 of POT-07-86, which is the QA summary report on the RCS Hydro deficiencies. The response to Deficiency #1 of POT-07-86 is being prepare Deficiency No. 2 (of P0T-07-86) lists the failures to make test deficiency reports (3) and to make entries in the test log (1). The first item concerns a temporary modification of a Differential Transmitter (2CHS-DT155), which was necessary to make it operable for the test. A log entry was made but no test deficiency record. It should have been an entry in the " Jumper and Lead Log Book". The DLC management response is to not make such a substitu-tion in the future tests. The inspector made two observations on this ite .

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The first was that the title " Jumper and Lead Log Book" is misleading be-cause all temporary system modifications are logged in this record. The second observation was that the Startup Manual (SUM) should be more defini-tive on this matter and should be revised to avoid future misunderstanding It should also be noted that only Test Deficiency Records were made during the RCS Hydro and not Test Deficiency Reports because the form for such a report did not exist in the SUM. This form was added to the SUM only re-cently. This one sheet form provides the technical details of the defi-ciency and the proposed resolution of the problem. It also mak's e the con-nection with the startup work reques The second item of deficiency No. 2 (of POT-07-86) deals with the failure to continue the recording of the RCS water temperature during the RCS pres-surization phase. The requirement for monitoring of the temperature was not neglected. It was, however, not recorded. It should be noted here that a record was made of the metal temperatures of all major RCS compon-ents as recorded by a multipen recorder which received its input from tem-porary thermocouples placed on the metal surface of these component These records (charts) were found to be retained by the test engineer rather than by the master test file (see section 3.2).

These data are more important now because the RCS water temperature data are not available to back up the conformance to Nil Ductility Temperature (NDT) criteria for the different components. The licens3e promised to follow up on the inspector's observations. This response will be tracked under Unresolved Item 86-18-02 (for metal temperatures).

The introduction of the Test Deficiency Report form was an essential manage-ment action to assure follow up on test deficiencie The response to Deficiency No. 3 (of P0T-07-86) deals with the apparent failure of the On Shift Operations Supervisor (OSOS) to acknowledge the start and the end of the test by signing off the test log at those times. In the response (ref.2) it is noted the SUM only requires the OSOS to sign off at the end of the test. Since the test was interrupted to perform system restoration, the OSOS was not notified of the end of the test. Management recommends that in future tests, the OSOS be notified of test interruptions. It is not stated in ref. 2 whether SUM revisions will be made to include this recommendatio All of the above observations were discussed with the DLC QA group. This group assured the inspector that these observations will be discussed with DLC management before closing out POT-07-8 Additional surveillance reports were received by the inspector on other preoperational tests. These reports will be reviewed by the inspector during a future inspectio Findings No violations were identified by the inspecto .

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. Plant Tours A plant tour was made through the following buildings:

Containment Building Auxiliary Building

Fuel Handling Building Emergency Diesel Generator (EDG) Building Control Roo The following observations were made by the inspector:

The Fuel Handling Building is in an advanced stage of constructio Cleanliness is good. Booties had to be wor *

In the EDG Building, inspection of the Colt Pielstick diesels revealed that these units have twin lube oil strainers rather than duplex oil strainers. With the twin units it is not possible to transfer from one unit tc the other because these units are arranged in parallel without valves to isolate them. In a duplex arrangement it is possible to switch oil flow from one to the other without having to shutdown the unit. The licensee was informed of the action taken at other nuclear plants, which have the same diesel engines, of going to duplex strainers to reduce the potential for engine shutdown from strainer cloggin . Exit Interview At the conclusion of the site inspection, on July 11, 1986, an exit interview was conducted with the licensee's senior site representatives (denoted in Section 1). The findings were identified and previous inspection items were discusse At no time during this inspection was written material provided to the licensee by the inspector. Based on the NRC Region I review of this report and discussions held with licensee representatives during this inspection, it was determined that this report does not contain information subject to 10 CFR 2.790 restrictions.

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ATTACHMENT A to 50-412/86-18 Procedure Reviews Proc. N Procedure Title Rev. N Approved JTG*

P0.2.10.01 Residual Heat Removal Test 0 12-26-85 P0.2.13.05 Quench Spray Chemical Injection 0 7-25-85 System Test P0.2.15.A.01 Primary Comp. Cooling Pumps 0 12-10-85 P0.2.21A.03 Main Steam Isolation and Bypass 0 12-18-85 Isolation Valve Operability Test, Cat. 1 P0.2.24.C.01 Steam Generator Level Instrumenta- 0 2-25-86 tion System Test -

SOV2.30.01 Standby Service Water Test 0 6-27-86

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ATTACHMENT B to 50-443/86-18 References for Section 4 (1) Test Procedure MTP-901, " Initial Operating Procedure for Manual Valves",

rev. 5, approved 3-14-8 (2) Test Procedures MTP-942, " Motor Operated Valve Initial Mechanical Checkout," rev. 1, approved 2-5-86 (3) Test Procedure ETP-802, " Control Circuit Checkout", rev. O, approved 4-18-83 (4) Test Procedure ETP-807, " Testing of Motor Operated Valves and Dampers using permanent power", rev. 2, approved 10-25-8 (5) Startup Work Request E-004674, for motor operated valve 2CCP-MOV-126, issued 5-30-8 (6) Test Deficiency Report (TDR) No. 2802, for motor operated valve 2CCP-MOV126, applicable test procedure ETP-8028807, approved 5-30-86 (7) Test Deficiency Report No. 2801, for motor operated valve 2CCP-MOV127, approved 5-30-8 (8) TDR No. 2591, for 2CHS*MOV275A, approved 3-25-8 (9) TDR No. 2766, for 25WS*MOV148A, approved 5-16-86 (10) TDR No. 1804, for 2SWS*MOV1168, approved 7-18-85

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(11) TDR No. 2348, for 2SWS*MOV563, approved 12-12-85 (12) TDR No. 1886, for 2SWS*MOV1076, approved 8-30-85 (13) TDR No. 2623, for 2CHS*LCV-115C85, approved 4-12-86 (14) TDR No. 2637, for 2RCS*MOV556, approved 4-11-86 (15) TDR No. 2761, for 2RCS*MOV556C, approved 5-14-86 (16) TDR No. 2634, for 2CHS*LCV115C, approved 4-11-86 (17) TDR No. 2052, for 2FNC-M0V100A, approved 6-13-86

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(18) TDR No. 960, for 25WS*MOV113A, approved 10-15-84 t

(19) TDR No. 1261, for 2CCP*MOV114, approved 11-3-84 (20) TDR No. 1265, for 2CCP*MOV157-2, approved 11-6-84

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(21) Non Conformance and Disposition Report (N&D) No. 33, 354, for Fuel Building (FB) Crane inspection, approved on April 30, 1986 by DLC/ SO (22) N&D 32795, for FB Crane Hoist, approved March 17, 198 (23) Test Certification Report for the New Fuel and Spent Fuel Crane, Mark N MHF-CRN227.

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ATTACHMENT C to 50-412/86-18 References to Section 5 (1) Duquesne Light Co. (DLC) Memorandum from R. J. Swiderski to C. E. Ewing,

" Responses to Surveillance No. P0T-07-86 (Deficiency No. 2)", dated June 6, 198 (2) DLC Memorandum from R. J. Swiderski to C. E. Ewing, " Responses to Surveillance No. POT-07-86 (Deficiency No. 3), dated June 9, 1986 4