IR 05000155/1989003

Insp Rept 50-155/89-03 on 890212-0325.No Violations Noted. Major Areas Inspected:Licensee Actions on Previous Insp Findings,Surveillance Activities Including Weekly & Monthly Tests on Various Components,Maint Activities on Components

ML20244C389
Person / Time
Site:	Big Rock Point File:Consumers Energy icon.png
Issue date:	04/06/1989
From:	Jackiw I NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20244C384	List: IR 05000155/1989003 ML20244C382
References
50-155-89-03, 50-155-89-3, NUDOCS 8904200176
Download: ML20244C389 (6)

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e U.S. NUCLEAR REGULATORY COMMISSION i

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REGION III

i Report No. 50-155/89003(DRP)

Docket No. 50-155 ' License No. DPR-6 Licensee: Consumers Power Company 212 West Michigan Avenue r Jackson, MI 49201

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Facility Name: Big Rock Point Nuclear Plant Inspection At: Charlevoix, MI 49720 Inspection Conducted: February 12 through March 25, 1989 Inspectors: E. Plettner N. Williamsen E. Swanson J. Hell r

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. Approved By: I N. Ja i ief, eactor rojects Section 2B klY Date Inspection Summary I Inspection on February 12 through March 25, 1989 (Report No. 50-155/89003(DRP))

l Areas Inspected: lhe inspection was routine, unannounced, and conducted by

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Senior Resident Inspectors and Resident Inspectors. The functional areas inspected consisted of the following: licensee actions on previous inspection findings; surveillance activities including weekly and monthly tests on various components; maintenance activities on various components, including the emergency diesel-onnerator coupling, a containment ventilation isolation valve, the backup core spray valve, repair of steam leaks, and removal of a condenser circulating water pump; operational, safety verification including the emergency i- condenser system and reactor shutdown and startu Results: The licensee has demonstrated a desire to respond in a timely manner to issues and concerns presented to them by the NRC. The surveillance, maintenance, and operational safety programs appeared to be performed in i a manner to ensure public health and safety. No significant safety items were identified in this repor PDR aDOCK 05000155 's Q PDC

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.- DETAILS

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1.- -Persons Contacted

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• T. Elward,jP1 ant Manager .

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- R. Abel, Production and Performance Superintendent-

) G. Withrow, Engineering Superintendent-'

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. H. Hoffman, Maintenance. Superintendent'

• L. Monshor, Quality, Assurance, Superintendent- ,

• Bielinski, acting:0perations. Supervisor W. Trubilowicz, Operations Supervisor

• G. Petitjean, Acting Engineering Superintendent-R. Buckner, Nuclear Training Administrator

• T. Pence,' Acting Nuclear Training Administrator

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. Donnelly, Nuclear Assurance Administrator

• McIntosh, Acting Nuclear Assurance Administrator

• Raciborksi, Acting Maintenance Superintendent

• J. , Beer, Chemistry / Health Physics Superintendent

• R. Alexander,' Technical Engineer

• E. Zienert, Director Human Resources The inspectors also contacted other licensee personnel in the Operations, Maintenance, Engineering, Radiation Protection, and Technical Department * Denotes those present at exit intervie . Licensee Action on Previous Inspection Findings The following items have been administratively. closed during this inspection period based on the length'of time the items have been in existence and the recognition of their limited safety significanc (Closed)OpenItem(155/85021-01]: Valve Maintenance Evaluatio (Closed) Open Item (155/85021-02): QA Enhanced Performanc . Monthly Surveillance Observation (61726)

Station surveillance activities listed below were observed to verify that the activities were conducted in accordance with the Technical Specifications and surveillance procedures. The applicable procedures were reviewed .for adequacy, . test and process instrumentation was verified to.be in their current cycle of calibration, personnel performing the tests; appeared to be qualified, and test data was reviewed for accuracy and completeness. The NRC inspectors ascertained that any deficiendes identified were reviewed and resolved. The NRC inspectors observed the licensee ls performance of the following surveillance tests on the indicated dates:

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February 13, 1989 T7-20, " Diesel Fire Pump Auto Start," Rev. 20, October 4, 198 March 8, 1989 T7-33, " Weekly Check of- ASD System Equipment,"

Rev. 1, February 2, 1989 March 15, 1989 T30-29, "RDS Cabinet Test (Sensor Cabinet B/

Actuation Cabinet 2)," Rev. 2, March 15, 198 March 22, 1989 T30-49, " Monthly Source and Response Check of Off-Gas Monitors," Rev.1, December 2,198 March 22, 1989 T30-51, " Monthly Circulating Water Discharge Grab Sample for Dissolved Gases", Rev. 1, November 23, 198 No violations or deviations were identified in this are . Monthly Maintenance Observation (62703, 40500)

Station maintenance activities of safety related systems and components listed below were observed / reviewed to ascertain that they were conducted in accordance with approved procedures, regulatory guides and industry codes or standards and in conformance with Technical Specification The following items were considered during this review: the limiting conditions for operation were met while components or systems were removed from service; approvals were obtained prior to initiating the work; activities were accomplished using approved procedures and were inspected as applicable; functional testing and/or calibrations were performed prior to returning components or systems to' service; quality control records were maintained; activities were accomplished by qualified personnel; parts and materials used were certified; radiological and fire prevention controls were implemente On February 16, 1989, one of eight bolts on the coupling between the emergency diesel engine and its generator broke while performing the weekly surveillance test, T7-28, " Emergency Diesel Generator Auto Test Start." The licensee entered a three-day Limiting Condition of Operation (LCO) to perform repairs. The coupling was disassembled and assessed for damage. The examination revealed the only failure to be a broken bol The licensee realigned the generator with the diesel and installed all new bolts in the coupling. The repair was completed and the emergency diesel generator was declared operable at 5:00 p.m. , February 18. The licensee is evaluating the root cause. Preliminary results from a laboratory indicate that the bolt met the specifications and that the failure was primarily the result of twenty years of usag During a routine inspection of the plant on February 22, 1989, the NRC inspector found a torn seal on one of two containment ventilation-supply isolation valves. The licensee was notified and took immediate corrective actions to install a new seal following Procedure No. MCIS-9, " Adjustment /

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Cleaning or Valve Seat Replacement of Sphere Ventilation Valve.". The licensee completed the repair and declared the valve operable at 8:33 p.m.,

February 22. The licensee is evaluating the preventive maintenance program for possible augmentatio 'On February 28,1989, at 9:00 p.m. 'during a monthly surveillance test,  :

the backup core spray valve failed to complete a full stroke testing in the remote manual mode which utilizes a " momentary contact" control switch. Subsequent manual valve operation was satisfactorily performed by the operator holding the control switch in the desired operating  ;

position ("open" or "close") until. valve motion was completed. The licensee proved valve operability for automatic operation. The licensee has taken adequate action to ensure that the valve will fulfill its intended function in remote manual mod The licensee entered a four-day maintenance outage on March 9, 1989, I which included the repair of various valve-stem and flange steam leak The No.1 condenser circulating water pump and motor were removed and shipped offsite for repairs. The resident inspectors observed the l activity on the circulating water pump and moto All scheduled repairs  !

were completed on March 12 and a plant startup was commence Work requests were reviewed to determine status of outstanding jobs-and to assure that priority was assigned to safety related equipment maintenance which may affect system performance, f The NRC inspectors observed the licensee's performance of the following ,

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maintenance work orders on the indicated dates: 1 February 18, 1989 No. 89-EPS-0033, dated February 17, 1989, to repair the coupling on the emergency diesel generato l February 23, 1989 No. 89-CIS-0007, dated February 22, 1989, for replacing ~the valve-seat seal on the containment ventilation supply side isolation  !

valve, CV-409 March 10, 1989 No. 88-CWS-0026, dated December 19, 1988, for

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removing and repairing the No. 1 circulating water pump and moto ,

March 15, 1989 No. 89-FWS-0015, dated March 14, 1987, for cleaning the instrument air-nozzles on the i pneumatic feedwater control syste )

1 No violations or deviations were identified in this are l

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. Operational Safety Verification (71707)

The NRC. inspectors observed control room operations, reviewed applicable logs, and conducted discussions with control room operators during the inspection period. Instrumentation and recorder traces were examined for abnormalities and discussed with the control room operators, as were the status of control room annunciators. Reviews were. conducted to confirm that the required leak rate calculations were performed and-within Technical Specification limit A system walkdown was performed to verify the operability of the Emergency Condenser system. Tours of the containment sphere and turbine building were conducted to observe-plant equipment conditions, including potential fire hazards, fluid leaks, and excessive vibrations and to verify that maintenance requests had been initiated for equipment in need of maintenance. Radiation protection ~ controls were inspected, including radiation work permits, calibration of radiation detectors, and proper posting and observance of radiation and/or contaminated areas. The inspector observed site security measures including access control of personnel.and vehicles, proper display of identification badges for personnel within the protected area, and compensatory measures when security equipment had a failure or impairmen The NRC inspector accompanied an auxiliary operator on his tour to observe him in the performance of his duties. The operator appeared to be knowledgeable and compecen The resident inspectors,'while performing routine inspections of plant areas, noted numerous minor deficiencies in electrical junction boxes and the lack of hand-wheels on some non safety-related valves in the service water system. The licensee was notified and took prompt corrective actio On March 2, 1989, the licensee determined that various valve-stem and flange steam leaks were contributing to an unidentified primary system leak rate of 0.47 gpm. The licensee made a conservative decision to shut down for maintenance before reaching the administrative limit of 0.8 gpm .

or the. Technical Specifications limit of 1.0 gpm. On March 8 at 8:05 the licensee commenced shutdown of the reactor. The resident inspectors observed that the shutdown was performed in a professional manner with detailed procedures, including 0-TGS-1, an Operations procedure for the Turbine Generator System, entitled " Master Check-Off Sheet," Rev. 63, dated February 21, 1989; General Operating Procedure (GOP) 7, " Plant Shutdown to Cold Shutdown," Rev.106, dated October 29, 1987; and Technical Data Book 15.5.I.2, " Control Rod Withdrawal and Insertion Sequence Cycle 23," Revision 82. The shutdown was completed on March 9 at 9:38 a.m. EST. The licensee completed all scheduled repairs and commenced a reactor startup on March 12. The resident inspector observed the startup and reviewed Procedure 0-TGS-1, " Master Check-Off Sheet" and GOP-1, " Plant Start-Up from Cold Shutdown," Rev. 115, dated May 16, 198 The reactor was critical at 1:53 a.m. , March 13, and the generator was placed on-line later in the day. With only a single circulating water pump in operation, the reactor power was limited to 75 percent of rated powe . - _ - _

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On March 15, 1989, the resident inspector attended the weekly meeting of the Chemistry / Health Physics Department. Cooperation between Maintenance, Operations, and Chemistry / Health Physics personnel was discussed. A supervisor reminded the staff to be attentive when using the brass tags which administratively control access to containmen Instruction was given on Procedure 5.3 (Vol. 1), "ALARA Work Documentation and Review," Rev. 1, May 25, 1988. The resident inspector addressed the group regarding the need to maintain constant vigilance in health physics practices. The closing topic was a roundtable discussion of problems and solutions in the health physics are No violations or deviations were identified in this are . Exit Interview The inspectors met with licensee r. representatives (denoted in Paragraph 1)

throughout the month and at the conclusion of the inspection period and summarized the scope and findings of the inspection activities. The licensee acknowledged these findings. The inspectors also discussed  ;

the likely informational content of the inspection report with regard to

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documents or processes reviewed by the inspectors during the inspectio The licensee did not identify any such documents or processes as proprietar !

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