IR 05000155/1993002
| ML20034E875 | |
| Person / Time | |
|---|---|
| Site: | Big Rock Point File:Consumers Energy icon.png |
| Issue date: | 02/19/1993 |
| From: | Phillips M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20034E867 | List: |
| References | |
| 50-155-93-02, 50-155-93-2, NUDOCS 9303020041 | |
| Download: ML20034E875 (44) | |
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l U.S. NUCLEAR REGULATORY COMMISSION-
REGION III
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Report No.
50-155/93002(DRP)
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Docket No.
50-155 L cense No. DPR-6 Licensee:
Ccnsumers Power Company
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212 West Michigan Avenue
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Jackson, MI 49201 i
Facility Name:
Big Rock Point Nuclear Plant
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Inspection A1.:
Charlevoix, Michigan
Inspection Ccnducted: January 5 through February 16, 1993 Inspector:
E.A. Plettner phr*f Approved By: 'M.
P. Phil 1ps, Chief 3//f/78 Reactor Projects Section 2B Date'
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i inspection Summary
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Inspection on January 5 through February 16. 1993
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(Report No. 50-155/93002(DRP))
Areas Inspected:
A routine, unannounced, inspection by the resident inspector of operational safety verification; maintenance and surveillarce activities; safety assessment and quality verification; followup of previcusly identified
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items; and followup of Licensee Event Reports.
Results:
Of the five areas inspected, no violations were idertified.
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unresolved item was identified in the safety assessment and qtality
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verification area dealing with commitment due dates for licensee event reports.
The surveillance, maintenance, and operational safety programs were implemented ir, a manner to ensure public health and safety.
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i 9303020041 930219 PDR ADOCK 05000155
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DETAILS 1.
Persons Contacted
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Consumers Power Company D. Hoffman, Vice President of Nuclear Operations
W. Beckman, Plant Manager D. Hughes, Executive Engineer
D. Turner, Maintenance Superintendent
W. Trubilowicz, Operations Superintendent _
G. Withrow, Plant Engineering Superintendent R. Alexander, Technical' Engineer T. Popa, Acting Chemistry / Health Physics Superintendent
M. Bourassa, Senior Licensing Technologist
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R. Scheels, Planning and Scheduling Administrator
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G. Boss, Reactor Engineer
. j R. Hill, Senior Consultant Quality Assurance
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Nuclear Regulatory Commission j
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L. Marsh, Director, Project Directorate III-1, NRR
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E. Greenman, Director, Division of Reactor Projects, Region III M. Phillips, Chief, Projects Section 2B, Region III
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All of the above attended the exit meeting on February 16, 1993.
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The inspector also contacted other licensee employees including members of the technical and engineering staffs, the reactor and auxiliary
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operators, and the security force.
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2.
Manaaement Meetinas (30702)
On February 16, 1993, a meeting was held between CPCo and the NRC
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representative at the Big Rock Point Nuclear Facilities. The purpose of
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the meeting was to update senior NRC management on the progress made by
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the licensee to improve performance in the area of plant maintenance and
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procedural adherence.
The NRC noted that good progress was being made in the preventive maintenance program.
Prioritizing the other programs for timely completion continues to warrant management attention.
Issues
dealing with the End of Licensee, regulatory impact, and the. licensee's
10 year operation plan were also discussed by the licensee.
The slides j
used by the licensee during the meeting are attached-to this inspection
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report.
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3.
Plant Operations
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Operational Safety Verification (71707)
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The inspector verified that the facility was being operated in'
conformance with the license and regulatory requirements and that
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responsibilities for safe operation of the facility.
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The inspector verified proper control room staffing and coordination'of plant activities; verified operator-adherence with.
procedures and Technical Specifications; monitored the-control
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room for abnormalities; verified that electrical power was
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available; and observed the frequency of plant and control-room i
visits by station managers.
The inspector also monitored various records, such as hold and
secure card records, jumpers and bypasses, shift logs and
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surveillance, daily orders, and maintenance items.
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i All operations were considered acceptable except as noted
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elsewhere in this report.
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On January 12 power was reduced to approximately 25 percent of
full power to allow repairs on a turbine high pressure casing
steam leak.
Repairs were completed and power was returned to
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approximately 95 percent of full power.
On January 21 power was reduced to approximately 25 percent of.
_i full power to allow repairs on the turbine bleeder trip valve'and
turbine intermediate pressure heater.
Repairs were completed and i
power was returned to approximately 95 percent of, full power.
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On January 27 the plant staff noted an increase in the off-gas l
flow rate. The cause of the problem was a crack in the: steam i
drain line from the turbine stop valve. Temporary repairs were
completed on February 6 with permanent repairs to be completed'
during the maintenance and refueling outage scheduled to start in
July 1993.
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Engineering department involvement was good in resolving the plant
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problems noted above.
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- No violations or deviations were identified.
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Maintenance / Surveillance (61726 & 62703)
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Work Observations i
Station maintenance and surveillance activities were observed and/or reviewed to ascertain that they were conducted in accordance with approved procedures, regulatory guides, industry codes and standards, and in conformance with Technical Specifications.
The following items were considered during this review: Approvals were obtained prior to initiating work; test instrumentation was calibrated; functional testing and/or calibrations were performed
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prior to returning' components or systems to service; quality
~i control records were~ maintained; activities were accomplished by'
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qualified personnel; results were within specification and
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properly reviewed, and any deficiencies identified were properly i
resolved. The following maintenance and surveillance activities'
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were observed:
i Maintenance M/0 93-FPS-0012
" Diesel Fire Pump Panel" to repair sensing j
line leak.
l Surveillance
T-30-20 Monthly Station Battery Readings T-30-41 Meteorological Data Acquisition System Test
The inspector attended the first meeting of the quarterly Repeat
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Maintenance Review Board. The meeting was attended by individuals-
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from various disciplines, including engineering, maintenance j
repair, quality control, and several plant superintendents..The-i basis for determining a repeat maintenance issue was discussed and
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the list of current repeat items was presented.
Individuals on
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the board were assigned items for follow up, due dates, and to
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provide a status report at the-next meeting if the task was not.
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completed. The number of repeat maintenance items has Seen high
in the recent year and the plant staff was trying to determine the i
root cause and develop corrective actions to prevent' recurrence.
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No violations or deviations were identified.
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,afety Assessment /Ouality Verification I
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Evaluation of Licensee Self-Assessment Canability (40500)
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The inspector attended several Corrective Action Review Board-
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(CARB) meetings during the inspection period. The CARB is required to assure prompt and adequate attention on event and
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deviation reports that are significant to safety. The CARB was
addressing a safety issue dealing with high pipe tunnel i
temperature and the effect this had on the Electrical
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Environmental Qualified (EEQ) listed equipment located in the pipe
tunnel. The members of the CARB focused only on the high j
temperature issues and failed to address the issues of the high humidity present in the room because of the steam leaks which were
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causing the high temperature and should an increased frequency of
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testing be considered to assure operability of the' equipment. The
CARB took. action on these issues _after being made aware of these
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Followup of Previously identified items (92701)
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(Closed) Violation 155/91005-01(DRP):
" Failure to follow j
Procedures." This violation involved three separate.
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examples where personnel failed to follow procedures. The 91005-01A example involved " Shift Turnover Procedure" TI-08,
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where limiting conditions for operation were not' logged as
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required. Corrective actions taken by the licensee. involved s
i training of personnel, revising the T1-08 procedure, and to evaluate the combining of the status board with the
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computerized notepad. The inspector verified that training-of personnel was completed on September 30, 1991, revisions
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to Shift Turnover Procedure TI-08 were completed on June 12, 1991, and the evaluation on the status board and
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computerized' notepad was completed on January 3,1992, with 1l the decision to leave them as separate items. The 91005-01B
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example involved Administrative Procedure 3.1.1.4, " Jumper,
'i Links and By-Passes / Temporary Modifications," and associated i
Surveillance Procedure T90-17, " Control Room Caution Tag Ledger /JLB Quarterly Review," which lacked documentation as -
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required to determine status of the modification.
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Corrective actions taken by the licensee were to revise the-l procedures and-provide training to appropriate personnel.
The inspector verified that training of personnel was completed on November 19, 1991, revisions to Administrative
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Procedure 3.1.1.4 were completed on August 4, 1991, and i
revisions to Surveillance Procedure T90-17 were completed on September 6, 1991. The 91005-01C example involved Operating i
Procedure 50P-30, " Control Rod Dr.. System," where the plant manager had not been notified of a problem and no
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deficiency report was completed as' required.
Corrective
action taken by the licensee was to revise the procedure.
The inspector verified that the revision to Operating Procedure SOP-30 was completed on September 20, 1991.
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Generic corrective actions taken by the licensee were to.
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again embark on a procedure upgrade program to be completed t
in December 1993.
The licensee provided an update on.the
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program's progress to senior NRC management during the currently scheduled quarterly management meetings. This
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item is closed.
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(2)
(Closed) Unresolved Item 155/91009-Ol(DRP):
" Post-Maintenance Testing and Operability of Support Systems."
_i This item involved the lack of post-maintenance testing i
instructions or acceptance criteria to determine if the i
support system was operable. The licensee has taken j
corrective actions to revise the maintenance order procedure
(3.2.1) and forms to identify the need for post-maintenance I
testing prior to returning the equipment to service. This item is closed.
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(Closed) Violation 155/91014-01(DRP):
" Failure to Take
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Corrective Action." This violation involved a degraded
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condition on a safety related component for which corrective
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actions were not promptly taken by the licensee. Corrective
actions were to revise the procedures and to distribute a letter to the shift supervisors discussing expected actions
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when performance anomalies are identified.
The inspector reviewed Revision 24, dated March 2, 1992, of Procedure T7-
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20 and Revision 21, dated March 3, 1992, of Procedure TSD-01
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to verify that the appropriate changes were incorporated in the new revisions. The letter to the shift supervisors was.
issued on November 26, 1991. This item is closed.
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(Closed) Unresolved Item 155/91014-02(DRP):
" System Operating Procedure used in Post-Maintenance Test." This
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item involved three factors that contributed to a
misdiagnosis of a problem related to the control rod drive
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poppet assembly repair. The licensee took corrective'
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the maintenance procedure (MCRD-3), and the maintenance order procedure (3.2.1) and forms to identify the need for post-maintenance testing prior to returning the equipment to service. This item is closed.
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(5)
(Closed) Unresolved Item 155/91024-05(DRP):
" Breakdown in Radiological Controls." The item became Licensee-Event Report (LER)92-003. The LER became part of Violation 155/92005-02(DRSS). The violation was closed in Inspection Report 155/920ll(DRSS).
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(Closed) Open Item 155/92020-Ol(DRP):
" Heat Exchanger Failure." This open item involved the cause for the heat exchanger tube failure. The licensee sent the failed
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component to the metallurgical laboratory for examination.
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The examination identified the cause of failure to be
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intergranular stress corrosion cracking. The cracking started because of poor fabrication process by the manufacturer. The licensee is evaluating similar heat exchangers used in the plant for replacement during the upcoming refueling outage scheduled for July 1993 to prevent a recurrence of the problem. This item is closed.
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(Closed) Open Item 155/92020-02(DRP):
" Foreign Material in RCP Motor Upper Lube Oil Cooler." This open item involved the source of the foreign material found in the flexible hose coupling of the lube oil cooler. The licensee did not perform any laboratory tests to identify the material and
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was unable to definitively determine the source of the
material and thus the root cause of the failure.
Instead,
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the licensee assumed the material to be pipe scale and no r
additional follow-up or corrective actions were taken. This item is closed.
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Followun of Licensee Event Reports (LERs1 (90712 & 92700)
The inspector reviewed the following Licensee Event Reports (LERs)
for compliance to reporting requirements and, as applicable, for implementation of appropriate corrective actions.
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(Closed) LER 91-011:
" Failure to Establish Air Lock l
Interlock Required For Containment Integrity."
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(Closed) LER 92-003:
" Maximum Stay Time not Provided on
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RWP."
This LER became part of Violation 155/92005-02(DRSS).
The violation was closed in Inspection Report 155/920ll(DRSS). This item is closed.
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(Closed) LER 92-007:
"RPS Actuation with Control Rod Motion
During Drive Testing."
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(Closed) LER 92-008:
" Loss of #1 Station Power 125 VDC System." The LER became violation 155/92017-03(DRP). The licensee response to the violation included the corrective actions contained in the LER, plus four additional corrective actions. The violation will be closed in a subsequent report when the corrective actions in the violation are completed.
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(Closed) LER 92-011:
" Fire Brigade Below Five Member Requirement."
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(Closed) LER 92-012:
" Shutdown Required by Facility Technical Specification Exceeding Unidentified Primary System Leakage Limits."
On January 20 during the review of all outstanding LERs for possible closure the inspector noted that Licensee Event Report (LER)91-013 had a due date of December 31, 1992, that was exceeded.
LER 92-002 had a due date of October 1, 1992, that was
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exceeded.
LER 92-009 also had a due date of October 1, 1992, that
was exceeded.
In all of these cases, no notice was provided to the licensee's licensing department, nor was the NRC notified of the original slippage of the due date.
Section 6.8.1 of the Technical Specifications states in part, " Written procedures shall be established, implemented, and maintained for all structures, systems, components, and safety actions defined in the Big Rock Point Quality List." Section 5.2 of Chapter 13 of Volume 17 of I
the Quality List requires procedures for administrative activities including licensing.
Section 4.2 of Administrative Procedure 1.3
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" Corrective Action" states in part that the originator of a corrective action document shall inform licensing of any changes including due date changes on any actions that respond to a NRC commitment.
In addition, the Office of Nuclear Reactor Regulation issued a letter dated December 17, 1992, which recommended that the licensee discontinue the practice of assigning target dates to LER commitments. Given the licensee's failure to inform the
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. appropriate groups of commitment date ' extensions 'and the above NRR i
position, this is an unresolved item pending resolution of
reporting requirements concerning action completion dates between Nuclear Reactor Regulation and Region III (155/93002-01(DRP)).
One unresolved item and no deviations were identified, j
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Unresolvcd Item
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Unresolved items _ are matters about which more information'is required in order to ascertain whether they are _ acceptable items, violations, _ or
deviations. An unresolved item disclosed during the inspection is
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discussed in Section 5.b of this report.
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Exit Interview The inspector met with' licensee representatives (denoted in paragraph 1)
at the conclusion of the inspection on February 116, 1993. The inspector summarized the purpose and scope of the inspection and the findings.
The inspector also discussed the likely informational content' of the inspection report, with regard to documents or processes reviewed by-the
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inspector during the inspection. The licensee did not identify any such
documents or processes as proprietary.
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l Attachments: As stated
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GOAL DEVELOP THE PROCESS TO OPERATE AXD REGELATE A
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PLAYI' SAFELY AXD ECONOMICALLY AS IT
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APPROACHES END-OF-LICENSE @OL)
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END-OF-LICENSE ISSLES
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IRBIAN RESOURCES PLAN NEEDED FOR CPCo AND NRC O
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o SYSTEMATIC ASSESSMENT OF LICENSEE PERFORMANCE (SALP)
o ADEQUACY OF OPERATING AND MAINTENANCE /
CAPITAL BUDGETS
- GROUP AUTHORITY / CREDIBILITY
- OPERABILITY / IMPROVEMENT
- APPROPRIATE INSPECTION EFFORT
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- CONTINUOUS NRC PARTICIPATION
- PRIORITIZE WORKLOAD
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- SCREENING NRC INITIATIVES
- MICHIGAN PUBLIC SERVICE COMMISSION -
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- DECOMMISSIONING TASK FORCE
- UPGRADE PUBLIC AFFAIRS
- TIMELY MANNER / FLEXIBLE
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- MANAGEMENT OF AGING ISSUES
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o VENDOR SUPPORT / COMMITMENT
- MANAGENENT COMMITAENT
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- RETAIN CONSTRUCTION SITE l
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- CONSISTENT REGULATION
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- PREDICTABILITY
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PROCESS PROPOSALS - OVERVIEW A.
DEVELOP A HUMAN RESOURCE PLAN
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DEVELOP A COMMUNICATIONS PLAN
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DEVELOP A DECOMMISSIONING PLAN
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ENHANCE THE INTEGRATED PLAN l
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DEVELOP NRC REGULATORY FOCUS
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. S BIG ROCK POINT 10 YEAR PLAN-INDEX
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Mission Statement
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Plan Methodology 1:
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i Strategic Overview Department Responsibilities / Strategy j
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Performance Targets
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ATTACHMENTS
Annual Budget Projections
BRP Business Plan
Chemical Decon Plan e
Human Resource Plan (Later)
Licensing Strategy (Later)
Maintenance Rule Plan (Later)
Option Study (Later)
REFERENCED DOCUMENTS
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Decommissioning Plan (Later)
Living Schedule
Power Supply Cost Recovery Filing
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VilSSION S-ATE VIENT t
The Big Rock Point Plant will become the first BWR to achieve full design life by operating safely and efficiently until the year 2000.
PUR3OSE To communicate the strategy for accomplishing the NOD goal of Big Rock Point operation through the end of its operating license and decommissioning.- The objective is to operate BRP to the end of its license life in a safe, economic and reliable mode, while maximizing the opportunity to identify, understand and manage end of life issues through decommissioning.
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P an N etloc o ogy The methodology used in developing and maintaining
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the 10 year plan utilizes and incorporates the following
documents:
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Annual Budget Projections
BRP Business Plan
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BRP Option Study i
e Chemical Decon Plan
Human Resource Plan Licensing Strategy
Maintenance Rule Plan
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Source documents which are not housed in the 10 year plan but which interface with:the plan include:
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Decommissioning Plan
Integrated Resource Plan (MPSC Filing)
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e Living Schedule Power Supply Cost Recovery (MPSC Filing)
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Strategic Overview l
Mission
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The Big Rock Point Plant will become the first BWR to l
achieve full design. life by operating: safely'and
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. efficiently until the year 2000. --
Business Stratesies
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Safety Performance - Industrial, Nuclear, Radiation
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Reliability
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Assumotions
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- BRP will continue-to operate until the end of licensed life.
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BRP remains capable of operating at 75% annual
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capacity factor and total production cost, including
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fuel, of less than the avoided cost of replacement-
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power at $56/MWH..
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ERP will not seek license renewal and will not i
operate beyond year 2000.
BRP will not retain full core' off-load capability i
through the end of life.
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To meet the requirements of 10 CFR 50.75 the-plant will submit a preliminary decommissioning plan in 1995 and a final plan and environmental
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impact statement in 1998.
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Employee training will continue in support of
maintaining required skills.
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Cost containment measures will require close
attention to insure no compromise of reactor
safety occurs.
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a Big Rock Point Timeline
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1993 1994 1995 1996
'1997 1998 1999'
2000 2001 2002 2003 2004 Lose Full Core Offload Shuidown/ POL I
I Submit POL Appl Commence Decommissioning Prepare Prclim Plan grep Final Plap NRC Approve Final Plan l
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Submit Prelim Plan Flie Plan w/ MPSC '
Submit Final Plan
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BIG ROCK POINT
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SITE WORKLOAD STUDY
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The overall goal of the study is to identify and
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prioritize Big Rock Point workload and to make sure
the available manhours are being. worked on the
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most important items first.
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The worklist is unscientific in that no absolute rules were established for inclusion.
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Deviation Reports Actiorr item Records
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Engineering D.ept.- Projects Operations Concerns
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Other:large projects that required
multidepartment' support.
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February 16, 1993'
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BIG ROCK POINT
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SITE WORKLOAD STUDY
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The worklist did NOT include:
L Maintenance orders unless identified in the.above categories All Big Rock Point organizations, eg. Training.
- Open items (October) approx 400
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- Items resolved since October '92 146
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The current worklist totals
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February 16, 1993l
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BIG ROCK POINT
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SITE WORKLOAD STUDY-
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Open ER/DR's are trending down Aug ust 19 9 2................
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Open AIR's are trending.down
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October 1992
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January 31,1993
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Open Engineering Projects.....-..
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.Open Facility. Changes-29.
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Open Specification. Changes
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Open Setpoint Changes
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February 16, 1993
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