IR 05000155/1993013
| ML20059D180 | |
| Person / Time | |
|---|---|
| Site: | Big Rock Point File:Consumers Energy icon.png |
| Issue date: | 10/22/1993 |
| From: | Phillips M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20059D160 | List: |
| References | |
| 50-155-93-13, NUDOCS 9311020156 | |
| Download: ML20059D180 (8) | |
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4 U.S. NUCLEAR REGULATORY COMMISSION
REGION III
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Report No.
50-155/93013(DRP)
Docket No.
50-155 License No.
DPR-6 Licensee: Consumers Power Company 212 West Michigan Avenue Jackson, MI 49201 Facility Name:
Big Rock Point Nuclear Plant
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Inspection At: Charlevoix, Michigan Inspection Conducted: August 28 through October 19, 1993 Inspector:
R. J. Leemon C. E. Brown-R. L. Twigg Approved By: k b f/vtV m i 6/e a/.9 3 M.P.\\Rhilfips, Chief Date Reactor Projects Section 2B Inspection Summary Inspection on August 28 - October 19. 1993 (Report No.- 50-155/93013 (DRP))-
Areas Inspected:
Routine, unannounced inspection by the resident inspectors of operational safety verification (reactor feed pump trip), engineered safety feature system walkdowns, radiological controls, security, maintenance and i
surveillance activities, engineering and technical support activities, quality l
verification effectiveness, and management meeting.
Results: Within the seven areas inspected, no violations were identified.
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Special inspection reports (155/93014 and 155/93015(DRP)) discuss the apparent j
violations and areas of concern identified during this inspection period. The
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following is a summary of the licensee's performance during,this inspection j
period:
i Operations: Overall performance in this area was poor. The loss'of control of primary system pressure during the hydro resulted in an Enforcement
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Conference. A personnel error resulted in tripping of the reactor ' feed pump -
g and a forced power reduction.
However, a strength was noted in.that at the end of the outage, the licensee expended considerable resources to improve housekeeping, cleanliness, and material conditions of the plant; resulting in-
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the plant being in the best condition'it has been in years.
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Maintenance \\ Surveillance:
Overall performance in this area was good.
A weakness was noted in that the licensee did not provide a procedure for the removal or reinstallation of the motor for the reactor-protection system's
.(RPS) #2 motor generator (MG). sets since the work was considered to be within the " skill of the craft." Therefore, no-bolt torque requirements were
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designated and no torque wrench was used to tighten the mounting bolts. The loosened bolts resulted in the motor generator going out of alignment in a short time; thus, requiring repeated work activities.
However, a strength was noted in that outage planning and scheduling have improved compared to previous outages.
Radiation Protection: Overall performance in this area was good.
Significant
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reduction in the Man-Rem dose during the outage is considered a strength.
Enaineerino/ Technical Support:
Performance in this area was good. A strength identified was the implementation of system engineer-and in-plant engineer programs.
Quality Verification Effectiveness:
Performance in this area was. adequate.
A weakness was noted in. communicating lessons learned from Palisades to the staff at Big Rock. This is discussed in special inspection report
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No. (155/93015(DRP)).
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D1 TAILS 1.
Persons Contacted Consumers Power Company
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P. Donnelly, Plant Manager
- E. Bogue: Chemistry / Health Physics Manager
G. Boss, Systems and Project Engineering Manager
- M. Bourassa, Senior Licensing Technologist
- R. Garrett, Senior Plant Tech Analyst D. Hughes, Executive Engineer
- D. Moeggenberg, Engineering Supervisor
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- T. Petrosky, Public Affairs Director R. Scheels, Planning and Scheduling Administrator
- W. Trubilowicz, Operations Manager
- D. Turner, Maintenance Manager
- G. Withrow, Plant Safety and Licensing Director The inspectors also contacted other licensee employees including members-of the technical. and engineering staffs, and the reactor and auxiliary
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operators.
- Denotes those attending the exit meeting on October 19, 1993.
2.
Plant Operations
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a.
Summary of Operations The plant entered the 1993 refueling outage on June 26, 1993.
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Fin _al outage tests and startup preparations were completed, and the reactor was taken critical at'11:00 a.m., September 4,1993.
The generator was placed online at 4:23:a.m., September 5,1993, after a 71 day outage. When the Big Rock Point Nuclear Power '
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Plant resumed electrical generation on September 5,1993, it
became the oldest operating licensed nuclear power plant.
It surpassed the previous operating record of 30 years and 92 days:
held by the Yankee Rowe facility located in Massachusetts.
On September 16, 1993, the plant had a forced power reduction from 74 to 40 percent when a personnel error resulted in the tripping-of the #2 reactor feed pump.
The' plant.was returned to' full power and operated normally for the remainder of the period.
b.
Operational Safety Verification (71707)
The' inspectors verified that the facility was being operated _in'
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conformance with'the. license and regulatory requirements and that the' licensee's management was effectively implementing.-its.
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The inspectors verified proper control room staffing and
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coordination of plant activities, verified operator adherence to procedures and technical specifications (TS), monitored the control room for abnormalities, verified that electrical power was.
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available, observed that management frequently toured the control
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room and the plant, and observed shift turnovers.
Operations did a good job of responding to the loss of the #2 reactor feed pump.
They performed a forced power reduction using appropriate abnormal procedure.s and prior training.
The inspectors reviewed various records, such as Caution-Tag.
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books, switching-and tagging-order files, shift logs and surveillances, daily orders, and maintenance work orders.
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Enforcement Conference An Enforcement Conference was held on October 12, 1993,.to discuss apparent violations and concerns relating to the breach of containment integrity and primary system over-pressurization events (Inspection Report Nos. 50-155/93014 and 50-155/93015).
Reactor Feed Pumo Trio On September 16, 1993, at 2:34 p.m., while cleaning the #2 reactor feed pump (RFP) lube oil pump, an auxiliary operator-(AO)
accidently bumped the " low lube oil pressure trip switch." This i
resulted in the #2 RFP tripping and subsequent manual trip of the i
- 1 reactor recirculating water pump (RCP), and a forced power reduction.
Power was reduced from 75 to 40 percent power.
A reactivity management briefing was held with the control operators to define their responsibilities and expected
indications during the RCP restart. The #1 RCP was started at
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3:33 p.m. in accordance with procedure SOP-29, " Nuclear Steam Supply System." At 7:50 p.m., the #2 RFP was restarted and power
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escalation was resumed to the previous level.
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Previously, the RFP had tripped due to the lube oil pressure switch being bumped.
The licensee' performed a human performance evaluation of deviation report (BRP-93053) regarding the RFP trip.
This evaluation of the trip of the #2 RFP will be' reviewed by the resident staff-(IFI 155/93013-01).
c.
Enaineered Safety Feature System Walkdown (71710)
The inspectors performed walkdowns of various safety systems.-using procedures and piping and instrumentation drawings.(P&lDs) to.
verify system line-ups and to ascertain that the systems were operable. During the inspections, housekeeping and_the material condition of valves, pumps, supports, labeling, and major system components were assessed and items needing attention were communicated to the licensee. At the end of the outage,.the.
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T licensee expended considerable resources to improve housekeeping,
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cleanliness, and material conditions of the plant; resulting in the plant being in the best condition it has been in years.
d.
Radioloaical controls
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The licensee management extended the outage schedule (originally
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49 days) to perform extensive turbine related work, resulting in a 71 day outage. The initial ALARA goal for the outage was to complete all work activities within a projected dose of 150 person-rem.
With improvements in planning and scheduling and
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minimizing the use of respirators, less than 120 person-rem was used even though the outage extended to 71 days.
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Security
On August 30 and 31, the security force performed well during drills conducted by an outside consultant.
The inspection did not reveal any safety-significant deficiencies.
No violations or deviations were identified in this area.
3.
Maintenance / Surveillance (61726 & 62703)
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Work Observations
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The inspectors observed station maintenance and surveillance
activities and determined that they were conducted in accordance with approved procedures, regulatory guides, industry codes and standards, and in conformance with TS.
I During this review, the inspectors considered the following:
(1) were approvals obtained before initiating work, (2) were instruments calibrated, (3) were functional tests and/or calibrations performed, (4) were quality control records properly maintained, (5) were activities accomplished by qualified personnel using " skill of the craft," and (6) were results within i
specifications and properly reviewed with any identified.
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deficiencies properly resolved before returning components or systems to service. The following maintenance and surveillance activities were observed.
b.
Maintenance
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Quarterly Battery Checks - Work Order (WO) 12301675/76.
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Reactor-Protection System Motor Generator - Work Order (WO)
12301420 - during the last outage, planned preventive maintenance removed, cleaned, and reinstalled the reactor-protection system's.
(RPS) #2 motor generator (MG) set.
The generator inboard bearings were defective and were replaced.
After 5 weeks of operation,
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i vibration on the MG's flywheel bearings increased by a factor of 10.
The most likely cause was determined to be a shift in the axial alignment between the MG motor and flywheel. The crafts
person who had conducted the alignment concluded that the most likely cause for the alignment shift was insufficient torque on
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the motor-to-bedplate mounting bolts which had allowed the motor-to shift and to degrade the alignment.
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Tightening of a bolt generally includes determining a torque value
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according to the bolt's type and s'ze.
The licensee did not provide a procedure for the removal or reinstallation of the motor since the work is considered to be within the " skill of the
craft.".Therefore, no bolt torque requirements were provided to the crafts person and no torque wrench was used to tighten the mounting bolts.
The bolts loosened resulting in the motor generator becoming_ misaligned in a short time; thus, requiring repeated work activities.
On September 30, 1993, the #2 RPS motor generator was removed from
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service for repairs.
Investigation revealed a 0.010 misalignment on one coupling.
Repairs were completed and the MG set was
returned to service on October 1, 1993.
The resident staff will
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follow the licensee's policy regarding torquing requirements (IFl 155/93013-02).
Removal, Repair, and Replacement of Reactor Depressurization System (RDS) Valves and Pilot Valves - W0s 12301240,12300748, and 12300628 - Review of an RDS valve replacement work package was
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found to include quality verification hold points for inspecting i
gasket integrity, internal valve cleanliness requirements, mounting-bolt torque settings, electrical connection conductivity checks, and external valve leak checks.
Environmental
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qualification (EQ) checklists were used to verify the suitability of EQ items.
The checklists included items for changes in location and environmental conditions, like-for-like component
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replacements, and mounting methods.
Individual sign-off blanks were provided in all of the packages to ensure that appropriate
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prerequisite plant configuration, personnel safety, and t'gging requirements were met.
Also, an engineering analysis for a replacement gasket of a different design was reviewed and found to be thorough.
The work package contained all the prerequisites'to perform quality work.
Outage Planning and Scheduling - The outage planning and
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scheduling improved greatly from previous outages.
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Surveillance
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Plant Hydro Test - The hydro test pressure exceeded the maximum i
test pressure and resulted in the lifting of a steam safety relief j
valve.
This event was discussed in an Enforcement Conference held i
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with the licensee on October 12, 1993.
Details are contained in
special inspection report Nos. (155-93014 and 93015(DRP)).
J No violations or deviations were identified in this report.
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Enoineerina and Technical suonort (37700)
The inspectors evaluated the extent to which engineering principles and'
evaluations were integrated into daily plant activities.
This was
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accomplished by assessing the technical staff's involvement in non-routine events, outage related activities, and assigned TS
surveillances; by observing on-going maintenance work and troubleshooting; and by reviewing deviation investigations and root cause determinations.
During this period, the system engineers were assigned their systems.
which they followed throughout the outage.
The in-plant engineer.
program was initiated.
This engineer spends the week working with the plant staff to provide engineering help where it is needed on a real time basis.
Preventive Maintenance Validation Proaram Status The inspectors reviewed progress on the licensees preventive maintenance (PM) validation program, which began in late January 1993.
By early June 1993, the Big Rock Point unique reliability centered maintenance (RCM) validation process had been developed and used to evaluate pre-determined activity control (PPAC) tasks for two pilot systems.
Parallel efforts to develop necessary computer work station software was also completed and software testing had commenced. A total of '23 of the 46 systems, containing over 2000 of approximately 2500 tasks in the PPAC
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system database, had been evaluated by the end of September 1993.
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four systems have been technically reviewed and approved. The target completion dates for these activities remain the same with changes to
the 1994 refueling outage PPAC's being implemented before the outage, and 75 percent of all approved changes implemented by the end of 1994.
After existing PPAC tasks are evaluated, the licensee will begin.the-
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critical component evaluation process with a target completion of
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June 30, 1994.
Program impact on the'recent refueling outage was limited to pilot-systems (control rod drive and reactor protection) PPAC-
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tasks. Task frequency adjustments eliminated a few tasks from the 1993 refueling outage, which helped to minimize personnel radiation'-
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exposures.
In particular, one dose intensive. activity was found to be
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unnecessary, resulting in saving approximately l' person-rem.
A side i
benefit of the technical review process is that system. engineers are-
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developing a better understanding of PPAC and non-PPAC' activities zi associated with their assigned' systems.
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The inspectors will continue to monitor the implementation of-this
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initiative and the results derived from it.
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No violations or deviations were identified.
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5.
Quality Verification Effectiveness (40500)
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The inspectors evaluated the effectiveness of management control, verification, and oversight in the jobs observed during this inspection.
The inspectors also attended management and supervisory meetings involving plant status to observe inter-departmental communications and coordination.
Additionally, the inspectors routinely monitored the results of the licensee's corrective actions programs by attending routine meetings; through discussions with the plant staff; and review of deviation, event, and root cause evaluation reports.
The communication of lessons learned at Palisades regarding the loss of
command and control of work activities to the staff of Big Rock Point was considered a weakness.
This is discussed in special inspection
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report No. (155\\93015(DRP)).
No violations or deviations were identified in this area.
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6.
Meetinas and Site Manaaement Visits
Ouarterly Manaaement Meetina A quarterly management meeting between the NRC and the licensee was held at Big Rock Point on October 1,1993. Topics discussed included: a) the
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1993 refueling, b) improvements in as low as reasonably achievable
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(ALARA) dose reduction, c) system engineers program, d) preventive maintenance and e) operating department initiatives.
8.
Exit Interview The inspectors met with licensee representatives (denoted in paragraph 1) on October 19, 1993.
The inspectors summarized the purpose and scope of the inspection and the findings. The inspectors also discussed the likely informational content of the inspection report, with regard to documents or processes reviewed by the inspectors during the inspection.
The licensee did not identify any such documents or processes as proprietary, 8