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%' ' N L Georgia Power Company7333 Pc1mont Avenue ,

:I- D "W . * = Atlanta. Georg:a 30308]*' *

. g; - Telephorie 404 526 3195 '!

Maing Address -,

.u% ' 40 inverness Conter Parkway+ , Post Offce Dax 1295'

. Birmingham, Alabama 35201,,

Telephone 205 868 558J ~> i'

t!e souttwvn m:ke sn tem1

W. G. Hairston, lit i

Senior Vce President |Nuclear Operations

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November 6, 1989 Is .

'

O.S.! Nuclear Regulatory Commission '

' ATTN: Document Control Desk .IHashington, D.C. 20555

1

PLANT HATCH - UNIT 1 :

NRC DOCKET 50-321 ,

OPERATING LICENSE DPR-57 i

LICENSEE EVENT REPORT,

DIESEL GENERATOR 1B INOPERABLE DUETO INSTALLATION OF INCORRECT PART -

Gentlemen:

In accordance with the requirements of 10 CFR 50.73(a)(2)(i), GeorgiaPower Company .is submitting the enclosed Licensee Event Report (LER)concerning the inoperability of the IB diesel generator due to theinstallation of an incorrect part. This event occurred at Plant Hatch -Units 1 and 2.

Sincerely,1

g.h., $Y _ ,)}pH. G. Hairston, III

1

JKB/eb

Enclosure: LER 50-321/1989-015

c: (See next page.)'

,

8911150103 891106PDR ADOCK 05000321 rh

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; . 'U.S. Nuclear Regulatory Commission~ November 6, 1989y 'Page_Two

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c: Georaia Power Company

Mr. H. C. Nix, General Manager - Nuclear Plant'

Mr. J. D. Heidt, Manager Nuclear Engineering and Licensing - HatchGO-NORMS

U.S. Nuclear Regulatory Commission. Washinaton. D.C.Mr. L. P. Crocker, Licensing Project Manager - Hatch

U.S. Nuclear Reaulatory Commission. Region IIMr. S. D. Ebneter, Regional AdministratorMr. J. E. Menning, Senior Resident. Inspector - Hatch

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0362V

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Peren ses * U s. NUCLE AA kE1ULATORY COMMISSION

, APPROvtD OMS NO. 3166-0184*

LICENSEE EVENT REPORT (LER) **''a'*''8''"

PACILITY 8eAME Hi DOCKET NUMBER 121 FAGE G

PLANT HATCH. UNIT 1 0161010101312 D 1 |oF| 017ftTLS 646

| D/G 1B INOPERABLE DUE TO INSTALLATI0k 0F WRONG PART'

GVSNT DATE Ill LER NUMBER (61 REPORT DATE 17) OTHER P ACILITIES INVOLVED (el |

MONTH DAY YEAR YEAR ''N *b ",'/,",$ MONTH DAY YEAR F ACILif v N Auks DOCKET NUMBERi$ln

Plant Hatch Unit 2 0 15101010 3 1 6 16 )1

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1 |0 ) |9 89 8|9 0 |1|5_

0|0 1|1 0|6 8! 9__

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THIS REPORT IS SusMITTIO PUREilANT TO THE REQUIREMENTS OF 10 CPR |- (Casc4 ene er aiore of she fonowmal lit)OPE RATING8800E m)

1 20.402(bl_

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.lCENSEE CONT Af17 FOR THIS LEtt H2) !

NAME TELEPHONE NbMBER

ARE A CODE

Steven B. Tipos. Manaaer Nuclear Safety and Compliance. Hatch 911I2 31617 I -17 i 81 SilCOMPLETE ONE LINE FC R EACH COMPONENT FAILURE DESCRIBED IN THl0 REPORT H31j

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M $ AC. R{ORTAgg "Aj[ R y,RT A,CAUS$ system COMPONENT , pq CAUSE sv8 TEM COMPONENT' s

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SUPPLEMENTAL REPORT EXPECTED 114) MONTH DAY YEAR

YES (If ven. temple,e txPECTIO SU049tS$1CN DATEI 9*O | | |A T R ACT a , . ,. . . ,,...e-, , , . -,,. , , n .,

L On 10/9/89 at approximately 0900 CDT, Unit 1 was in the Run mode atapproximately 2436 CMWT (approximately 100% of rated thermal power) and Unit2 was in the Refuel modo with all fuel removed from the core. At that time,procedure 34SV-R43-002-23, " Diesel Generator 1B Monthly Test," was being '

performed. While attempting a local, manual start of Diesel Generator (D/G)1R43-S001B per procedure, the D/G failed to start. Subsequent investigationrevealed that approximately two gallons of lubricating oil had accumulatedbetween the pistons of the number 2 cylinder, hydraulically locking thepistons. The oil accumulated as a result of an incorrect type of pump thathad been installed in the D/L's standby circulating lubricating oil cystem,

on 9/5/89. Monthly operability testing of D/G 1R43-S001B was completedsatisfactorily on 9/15/89, ten days after the incorrect pump was installedand placed in service. Therefore, it is concluded D/G 1R43-S0018 becameinoperable at some indeterminate point between 9/25/89 and 10/9/89. Theother four D/Gs were not affected by this event.

The root cause of this event is personnel error. The incorrect model numberhad been assigned to the warehouse stock number for the circulatinglubricating oil punip MPL number. Consequeritly, the incorrect type of punpwas issued and installed.

Corrective actions for this event include replacing the pump, draining thelubricating oil from the cylinders, visually inspecting the D/G, correctingthe model number assigned to the pump's stock number, changing the requiredfunctional test for pump repair / replacement, and performing a review of asample of D/G parts information.

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80AC Perm 384.. U.S. NUCLEA](.E!ULAroRY COMMr5SION |** . . ' UCENSEE EVENT REPORT (LER) TEXT C NTINUATION . mr.ovco oue wo sino-oio4

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EXPIRES: t/31/N.

f; @LirY agamt (gg DOCMt1 NUMSSR W LOR NUMSER le) PA06 (3) , 1

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PLANT HATCH, UNIT 1 o |510 lo io i 31211 81 9 0 11 'l 5 010 01 2 oF 017- -

rext ;., - . = w anc e m on

PLANT AND SYSTEM. IDENTIFICATION

General: Electric -' Boiling Water Reactor.

~ Energy' Industry Identification System codes are identified in the textp .as'(EIIS. Code XX).

;

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| . 1

SUMI1ARY OF EVENTL

OnL 0/9/89 at'approximately 0900 CDT, Unit 1 was in the Run mode at1

approximately 2436 CMWT (approximately 100% of rated thermal power) andI

Unit 2 was'in the Refuel mode with the Reactor Pressure Vessel head ;removed, the cavity flooded,'and all fuel removed from the core. At '

that time, procedure 34SV-R43-002-25, " Diesel Generator 1B MonthlyTest,"'was being performed. While attempting a-local, manual start ofDiesel Generator' (D/G, EIIS Code EK) 1R43-S001B per procedure, the D/G-

' failed'to start. Subsequent investigation revealed the D/G was-. hydraulically . locked. Approximately two gallons of lubricating oil hadaccumulated between the pistons of the number 2 cylinder, locking the j

' pistons. The oil ' accumulated between the pistons as a result of an - 1incorrect type of pump that had'been installed in the D/G's standby |circulating lubricating oil system (EIIS Code LA) during maintenance ;activities. performed on 9/5/89. Monthly operability testing of 'D/G l

-1R43-S001B was completed. satisfactorily on 9/15/99, ten days after the'irtorrect pump was installed and placed in service. Therefore, it' is

~

. concluded D/G-1R43-S0018 became inoperable at some indeterminate pointbetween. 9/25/89 and 10/9/89. The other four D/G's were not affected by.this event.

The. root cause of this event is personnel error. The incorrect modelnumber had been assigned to the warehouse stock number for the standbycirculating' lubricating oil pump (EIIS Code LA). Consequently, theincorrect' type of pump was issued from the warehouse and installed.

. Corrective actions for this event include replacing the pump with thecorrect type of pump, draining the lubricating oil from the cylinders,V!sually inspecting the D/G, correcting the model number assigned to thepap's stock number, changing the required functional test for pumpupir/ replacement, and performing a review of a sample of D/G partsinformation.

DESCRIPTION OF CVENT

On 9/4/89, Maintenance Work Order (MW0) 1-89-3940 was initiated on theStandby Circulating Lubricating 011 Pump,1R43-C006B, for D/G 1R43-S001B(1B D/G) to correct excessive tripping of the supply breaker. OnC/5/89, Maintenance personnel found that the cause of the breakertripping was a defective motor. In removing the defective motor, thepump had to be disassembled. As an alternative to rebuilding the pump,it was decided to replace it with a new pump. Accordingly, Maintenance

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esac Poem ageA U.S. NUCLEM 051ULAv0RY COMMISSION

'" M ' LICENSEE EVENT REPORT (LER) TEXT CONTINUATIEN er;.ovto ove' No. am-oms tXPIRES S/31/98

F AClLifV NAMS (H DOCRET NUMBER W LER NUMetR 10) PA05 (31 -

naa "Sm;',', ' 5 730'' '

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011|5PLANT 4ATCH. UNIT 1 015101010 | 31211 81 9 010 01 3 0F 0 17- -

vm c - . 4 M Nau as = !m . !personnel completed Stock Material Issue (SMI) requests for a new pump |,

L - and motor from an on-site warehouse. They obtained the stock numbers '

, corresponding to the. replacement pump and motor for pump 1R43-C006B and| entered that information on the SMI requests. This is per plant

,

| procedure for obtaining parts from the warehouse. Warehouse personnel,' |when given the properly completed and approved SMI requests, located the ;

pump and motor by the given stock numbers and issued them to the :requesting Maintenance personnel, j

lMaintenance personnel installed the new pump.and motor in the 1B D/G's jstandby circulating lubricating oil system. They then performed a 1

functional test of the new pump by verifying no oil flow into the upper )crankcase per procedure 52PM-R43-013-0S, " Diesel Engine Main and !Connecting Rod Bearing Inspection." Two maintenance foremen '

independently verified " oil not flowing into upper crankcase." The pumpwas placed into service.and the 10 D/G was declared operable. Monthlyoperability testing of the 1B D/G was completed satisfactorily on9/15/89.

..

On 10/9/89, Operations personnel began the performance of procedure34SV-R43-002-25 as part of another scheduled surveillance of the 1BD/G. At approximately 0900 CDT, a local, manual start of the D/G was !attempted as required by the procedure. The D/G failed to start. |Another attempt was made to start the D/G, but it also wasunsuccess ful . The 1B D/G was declared inoperable and Limiting i

Conditions for Operation (LCOs) 1-89-477 and 2-89-511 were initiated.|

Maintenance personnel began an investigation of the start failure. Theymanually rotated the D/G crankshaft, but could produce only 1/4 turn of 1

the crankshaft. This indicated the D/G was hydraulically locked. Upon'

inspection, it was discovered that approximately two gallons oflubricating oil had accumulated between the opposed pistons of thenumber 2 cylinder. This locked the pistons and prevented the engine ,

from starting. Approximately 20 gallons of lubricating oil also was I

found in the cylinders' exhaust line.

Further investigation revealed pump 1R43-C006B was continuously pumpingoil into the upper crankcase. Although the pump is designed to run j

continuously, the discharge head developed by the pump should be '

insufficient to allow oil to reach the upper crankcase at oiltemperatures above 102*F (normal oil temperature is approximately 135*F;the pump trips if oil temperature drops to 105"F).

The model number of the installed pump was checked and found to be.

incorrec'. The installed pump was a model HL75M rated at 20 gpm rather I

than the correct model H75M rated at 10 gpm. The incorrect pump hadbeen installed on 9/5/89 when the pump and motor were replaced. Theother four D/Gs were checked and found to have the correct pumpinstalled in their standby circulating lubricating oil systems,

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/ GIRCPer.n NSA" U.6, NUCLEAR G.ElVLATORY COMMISSION 1

!LICENSEE EVENT REPORT (LER) TEXT C NTINUATION.-A**. ovio ove No. siso-oio.

t g. EXP1Rit: 8/31/M| tyCitfTV IsAN4 (16 DocetET 8# UMBER (2) ggn gyuggn qq, paog (3)'

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PLANT HATCH, UNIT 1 o |s |o |o |o | 3|2 |1 8|9'

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The stock. number assigned to pump 1R43-C006B showed both pump modelnumbers, H75M and.HL75M; as appropriate. Both models were stored in thesame location in-the warehouse and, because they were both assigned tothe same stock number, were consideted acceptable for issuance as a i

replacement for pump 1R43-C006B. Both models were tagged with stocknumber 87120-30918 and MPL number 1R43-C006B. When the pump.and motorwere issued on 9/5/89, personnel obtained a pump tagged with the stock-

number and MPL number given on the SMI request. |) !

[ The outward appearance of the two pumps is almost identical. The only.difference is slight (one end face of the model H75M pump is' recessed 1

approximately one inch, the same end face of the model HL75M pump isalmost flush) and is not obvious without a detailed inspection. Theoverall size and shape of the two pumps are the same, consequently, tne -model HL75M pump fit into the standby circulating lubricating oil

_

. sy stem. When the incorrect pump was functionally tested, it was thoughtthat no oil was flowing into the. upper crankcase; however, oil flow isslow (on the order of a few drops per minute) and is difficult to detect.

The lubricating oil was drained from the cylinders and the exhaust lir.e,pump 1R43-C006B was replaced with the correct model (H75M), the 1B D/Gwas visually inspected with no damage identified, procedure

i34SV-R43-002-1S was successfully performed, and the D/G was declared '

operable at approximately 0140 CDT on 10/12/89. LCOs 1-89-477 and2-89-511 were terminated.

CAUSE OF THE EVENT '

The root'cause of this event is personnel error. The incorrect modelnumber (HL75M) was assigned to the warehouse stock number for pump1R43-C006B. .This resulted in model HL75M being tagged for use asStandby Circulating Lubricating Oil oump 1R43-C006B. Consequently, theincorrect model was issued and installed as pump 1R43-C006B on 9/5/89.It is inconclusive as to when the stock number was incorrectlyassigned.

Also contributing to this event was a less than adequate functional teston 9/5/89. The functional test for the new pump was performed using aportion of procedure 52PM-R43-013-0S. It consisted of removing theupper crankcase inspection covers and visually verifying no oil flowinto the upper crankcase. This functional test method is less thanfully adequate since it is very difficult to detect oil flow of thesmall magnitude experienced in this event.

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t'IIC f orm .1084 U S. DeUCLE AR RIOUL' TDRV COMW9510N ;'""_ ' ' LICENSEE EVENT REPORT (LER) TEXT C3NTINUATl3N urRo<eo ous No.sisowio..G- (KPIRE$. 8/31/N

PACILITT fBAMS til DOCKt." NUhIDER 40 ttR NUhtttR tel | PA06 (3)

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PLANT HATCH, UNIT 1 0151010101312 |1 81 9 Ol115 010 01 5 0F 0 I7 I- -

TEXT R move apses 4 #seused amo settaenst Mtc penn mW (In

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REPORTABILITY ANALYSIS AND SAFETY ASSESSMENT

i This report is required by 10 CFR 50.73'(a)(2)(1) because a condition| existed which was prohibited by the plant's Technicel Specifications.| 'Specifically, the 1B D/G was inoperable for an indeterminate period ofI time between 9/25/89 and 10/9/89 without the appropriate actions being

taken as required by Unit 1 Technical Specifications section 3.9.B and .iUnit 2 Technical Specifications section 3.8.1.2. |

'In this event, the 10 D/G was inoperable due to the accumulation oflubricating oil between the pistons of the number 2 cylinder as a resultof an incorrect type of. pump being installed in the standby circulating

<

!

lubricating oil system. The 1B D/G provides emergency power to Unit 1or Unit 2 emergency equipment in the event of a loss of offsite power.(LOSP). Each unit also has two other D/Gs which provide emergency powerto redundant emergency equipment in the event of an LOSP.

During the time period in question, 9/25/89 to 10/9/89, Unit 1 was atfull power with its other two D/Gs,1R43-S001A and 1R43-S001C operable.Therefore, two Unit 1 D/Gs were operable and one was not. This

l

,

condition has already been analyzed in Unit 1 Final Safety Analysis '

Report (FSAR) section 8.4.4. A detailed analysis of a loss of coolantaccident in conjunction witn an LOSP and the loss of one D/G is given inUnit 1 FSAR section 14.4.3. It was determined that "with one diesel outof service, the remaining diesel generator units are capable offurnishing power for safe shutdown" of Unit'1. Based on existinganalysis, it is concluded this event had no adverse impact on Unit l'snuclear safety.

During the same time period, Unit 2 was in the Refuel mode with no fuelin the vessel. Fuel movement was in progress in the Spent Fuel Poolcuring a portion of this time. Unit 2 Technical Specifications requireat least one D/G to be operable under these conditions. Thisrequirement was not met for an indeterminate period of time from 9/25/89to 10/1/89 when neither D/G 2R43-S001A (2A) nor D/G 2R43-S001C (20) wasoperable. D/G 2A was operable from 10/1/89 to 10/9/89.

There are two events which could occur during the Unit 2 conditionsstated above: a fuel handling accident and a loss of Spent Fuel Poolinventory. In a fuel handling accident, a spent fuel bundle is droppedduring movement resulting in damage to the bundle and releases ofgaseous fission products. This, in turn, would result in high radiationlevels on the Refueling Floor and automatic start of the Unit 1 and Unit2 Standby Gas Treatment (SBGT, EIIS Code BH) system filter trains. Evenif this event were to occur in conjunction with an LOSP (a highlyunlikely event), D/G 1 A and 1C wnuld provide emergency power to the Unit1 SBGT system. The two Unit 1 SBGT system filter trains are adequate tomaintain offsite doses within analyzed limits (see Unit 1 FSAR section14.4.4 ).

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002C Poem SPSA UO WUCLlia LE;U'.ATORY COMMISSION !

' " ' ' . . * -UCENSEE EVENT REPORT (LER) TEXT C2NTINUAT12N - geRono ous wo. mo-oio4 i' '

*EXPtRES: t!31/M

PACIUTY 88AME m DOClltiNUMSER W LER IdVMSIR 40) . PA06 (3)

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0|0 01 6 or 0 | 7iPLANT HATCH. UNIT 1 o is lo |0 |o | 312|1 8| 9 - 0 |1 | 5 -

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. A loss of Spent Fuel Pool invento'y is an analyzed event (Unit 2 FSARrsection 9.1.2.3.1 ) . If such an event were to occur concurrent with an ,

LOSP, emergency power would be needed to power safety related pumps to |

1 replace the lost SFP water. Due to the design of the Spent Fuel Pool, l

pumps powered by the 1 A and 1C D/Gs are capable of providing makeup to l'

the SFP.

Based on the above, it is concluded this event had no adverse impact onUnit 2's nuclear safety. Had this event occurred with Unit 2 at fullpower (as Unit 1 was), it would have had no' adverse impact on nuclearsafety since the 2A and 2C D/Gs would have been operable (they were out

i

of service for outage related work which would not have been performedduring operation). As on Unit 1, one D/G out of service has beenanalyzed on Unit 2 (Unit 2 FSAR sections 8.3.1.1.3 and 8.3.1.2.1) andfound not to prevent safe unit shutdown. Therefore, this event wouldnot have been worse had it occurred under other conditions.

CORRECTIVE ACTIONS

The lubricating oil was drained from the cylinders and the exhaust line, !pump 1R43-C006B was replaced with the correct model (H75M), the 1B D/G |

was visually inspected with no damage found, procedure 34SV-R43-002-1Swas successfully performed, and the D/G was declared operable atapproximately 0140 CDT on 10/12/89. At that time LC0's 1-89-477 and2-89-511 were terminated. Additionally, it was verified the correctmodel pump was installed in the standby circulating lubricating oilsystems of the other four D/Gs.

The incorrect model number was deleted from the stock number for thestandby circulating lubricating oil pumps and assigned its own uniquestock number. The two types of pumps were physically separated. Theynow are stored in different locations in the warehouse. The tags on thepumps were corrected to reflect the change in stock numbers and intendeduse.

The affected portion of procedure 52PM-R43-013-0S will be revised tochange the steps used as a functional test to make them more meaningfuland easier to perform (e.g., verify pump discharge pressure withinacceptable range). These changes will be made prior to use of theprocedure as a functional test following repair / replacement of the pump.

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IIRC Pere 330A- U.S. NUCLE *2 CEGULATORY C0heesem#0ef ,

'" ''' , 9 LICENSEE EVENT EEPORT (LER) TEXT CENTINtlATl!N APPa veo oue NO.3160 -0104-4

|5h'E EXPIRES: 8131/ND

PActL47V $$Atllt til DOCR4T NUtdBER (3) Ltn tsubseta tel PA06 (3)

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PLANT HATCH, UNIT 1 o |s [o lo lo | 3| 2 |1 819 0 |1 | 5 0|0 0|7 OF 0 |7:- -

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As of December 1988, stock numbers are assigned by plant NuclearProcurement Review Group personnel at the time of equipment requisitionreview while performing procedure 26MC-MTL-006-0S, " Requisition Reviewfor Quality Requirements." However, a review of a 10% sample of U/G

| parts on file will be performed by 3/1/90 The review will check thei part records for MPL number, stock number, and model number to ensureI this information is correct and the part's intended use is properly

identified. Further corrective actions (e.g., expanding sample size,'

4

physical walkdown of D/Gs) may be taken based on the results of thereview.

Since the persons responsible for assignment of the erroneous stocknumber could not be identified, no disciplinary actions have been takenagainst any individual.

ADDITIONAL INFORMATION

No systems other than the 18 D/G were affected by this event.

No similar events in which a safety system was rendered inoperable due 1

to the installation of a wrong part were noted. I

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