IR 05000244/1993024

Insp Rept 50-244/93-24 on Stated Date.No Violations Noted. Major Areas Inspected:Plant Operations,Maintenance & Plant Support

ML17263A531
Person / Time
Site:	Ginna
Issue date:	01/25/1994
From:	Lazarus W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML17263A530	List: IR 05000244/1993024 ML17263A529
References
50-244-93-24, NUDOCS 9402040002
Download: ML17263A531 (11)

Text

U. S. NUCLEAR REGULATORY COMMISSION

REGION I

Inspection Report 50-244/93-24 License: DPR-18 Facility:

R. E. Ginna Nuclear Power Plant Rochester Gas and Electric Corporation (RG&E)

Inspection:

Inspectors:

November 28 through December 31, 1993 T. A. Moslak, Senior Resident Inspector, Ginna E. C. Knutson, Resident Inspector, Ginna Approved by:

W.

, C 'ef, Reactor Projects Section 3B INSPECTION SCOPE Date Plant operations, maintenance, and plant support.

INSPECTION EXECUTIVESUMMARY Operations The plant operated at approximately fullpower for the majority of the inspection period. Power was smoothly reduced to 70 percent for a short duration to permit repair of a heater drain tank pump motor oil cooler leak.

Operators astutely identified the leak before equipment reliability was challenged.

Maintenance Cold weather preparations have been effective in identifying, correcting, and monitoring plant environmental conditions that could jeopardize equipment operation.

Plant Support Greater attention-to-detail is warranted in establishing radiation area boundaries prior to conducting radiography.

9'402040002 9'40127

<OR AnOCX OSO00aae Q

PDR

e TABLEOF CONTlPKS EXECUTIVE SUMMARY....................................

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i TABLE OF CONTENTS.......................................

ii 1.0 OPERATIONS (71707)........................

1.1 Operational Experiences 1.2 Control of Operations.'....................

1.3

"B" Heater Drain Tank Pump Motor Oil Cooler Service 1.4 Engineered Safety Features System Walkdown (71710)

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Water Leak.

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2.0 MAINTENANCE(62703; 61726)........

2.1 Corrective Maintenance 2.1.1 Routine Observations.......

2.2 Surveillance Observations 2.2.1 Routine Observations.......

2.3 Cold Weather Preparations (71714)

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3.0 PLANT SUPPORT (71707)

3.1 Radiological Controls....

3.1.1 Routine Observations 3.2 Secunty

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3.2.1 Routine Observations 3.3 Fire Protection........

3.3.1 Routine Observations

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4.0 Safety Assessment/Quality Verification....

4.1 Periodic Reports.............

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5.0 ADMINISTRATIVE(71707, 30702, 94600)

5.1 Deep Backshift Inspection.......

5.2 ExitMeetings...............

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DETAILS 1.0 OPERATIONS (71707)

1.1 Operational Experiences On December 20, 1993, plant power was reduced to 70 percent (the limitfor operation with a single heater drain tank pump in service) due to a service water leak in the "B" heater drain tank pump motor oil cooler.. Following completion of repairs, full power operations resumed on December 20, 1993.

The plant operated at full power (approximately 98 percent) for the balance of the inspection period.

1.2 Control of Operations Overall, the inspectors found the R. E. Ginna Nuclear Power plant to be operated safely.

Control room staffing was as required.

Operators exercised control over access to the control room.

Shift supervisors maintained authority over activities and provided detailed turnover briefings to relief crews.

Operators adhered to approved procedures and were knowledgeable of off-normal plant conditions.

The inspectors reviewed control room log books for activities and trends, observed recorder traces for abnormalities, assessed compliance with technical specifications, and verified equipment availability was consistent with the requirements for existing plant conditions.

During normal work hours and on backshifts, accessible areas of the plant were toured.

No operational inadequacies or concerns were identified.

1.3

"B" Heater Drain Tank Pump Motor Oil Cooler Service Water Leak On the morning of December 20, 1993, an auxiliary operator observed that the oil in the upper bearing sight glass for the "B" heater drain tank pump motor was cloudy.

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. upper bearing oil reservoir is cooled by a service water heat exchanger, water inleakage was immediately suspected.

Service water to the heat exchanger was secured and plant power reduction was commenced.

Power was reduced at one percent per minute to the point at which two HDT pumps were no longer required (70 percent), and the "B" HDT pump was secured.

The cause of the leak was found to be a pinhole in the tubing'that leads to the heat exchanger.

A similar failure had occurred with this heat exchanger four months earlier, as discussed in inspection report 50-244/93-16.

As had been the case'on that occurrence, the cause of the December 20 failure was suspected to be a combination of age-related wall thinning and localized oxidation produced by the sodium hypochlorite that is added to the service water system to reduce biofoulin The leak was repaired by replacement of the affected portion of tubing.

The service water leak had been discovered early enough to prevent the reservoir from overflowing into the motor.

Electrical testing and visual inspection verified that no motor rework was required.

The "B" heater drain tank pump was returned to service and full power operation was reached on the evening of December 20, 1993.

I The inspector observed a portion of the power reduction from the control room and found that the operation was well controlled and.conducted in accordance with operations procedure (O)-1.2, "Power Reduction."

Operators demonstrated excellent responsiveness and operational control in maintaining reactor axial flux difference within the target band throughout the rapid power reduction.

The inspector had no additional concerns on this matter.

1.4 Engineered Safety Features System Walkdown (71710)

The inspector conducted a detailed walkdown of a representative sample of accessible portions of the safety-related service water system.

Primary emphasis was placed on inspection of system material conditions for items that might degrade plant performance.

Items examined included installation of hangers and supports, housekeeping, material condition of valves, correct valve positions, and component labeling.

No safety-significant deficiencies were noted.

The inspector concluded that the material condition of the safety-related service water system was satisfactory and that the inspected portions of the system were properly aligned.

2.0 MAIN'H~WANCE(62703, 61726)

2.1 Corrective Maintenance 2.1.1 Routine Observations The inspector observed portions of maintenance activities to verify that correct parts and tools were utilized, applicable industry code and technical specification requirements were satisfied, adequate measures were in place to ensure personnel safety and prevent damage to plant structures, systems, and components, and to ensure that equipment operability was verified upon completion.

The following maintenance activities were observed:

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Work Order 19369941, "Repair Leaking Pipe Between V-5725B and V-5790 ["B" steam generator blowdown piping]," observed December 29, 1993 Maintenance observed was additional weld buildup, based on radiographic examination of the initial repair.

This was a temporary repair, with piping replacement scheduled for the 1994 refueling outage.

Radiographic examination of similarly configured blowdown piping for the "A" steam generator showed no thinnin Work Order 19369946, "Repair V-9519E," performed in accordance with maintenance procedure (M)-11.5K.2, "Turbine Driven Auxiliary Feedwater Pump Governor Control Valve (V-9519E) Inspection and Maintenance," revision 1, dated March 26, 1992, observed December 30, 1993 Maintenance to repair body-to-bonnet leak identified during performance testing that had been conducted the previous day.

Replacement of the gasket corrected the leak.

Troubleshoot Abnormal Noise From Control Rod Drive Motor Generator "B",

observed December 30, 1993 Initial investigation found the generator-end bearing to be in need of lubrication. After greasing, the machine was reassembled and operated satisfactorily.

Given that no maintenance beyond greasing was undertaken, the maintenance work package, originally developed to support this work, was not maintained.

AdditionaOy, the inspector noted the following:

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On December 17, 1993, the inspector n main steam check valve CV-5219 was oted that one of the two counterweights on working its way offof the valve disc pivot shaft.

The counterweight is keyed to the shaft, and thus was retained in its proper orientation; however, the axial retaining bolt had sheared and vibration was causing the counterweight to move towards the end of the shaft.

The counterweights serve only to aid check valve opening under light load; therefore, this deficiency did not affect the safety function of the valve. In response to this deficiency, the counterweight was pressed back to its original position on the shaft, and periodic checks were instituted to ensure that it remained in place.

Repair willbe accomplished during the 1994 refueling outage.

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Over the course of the inspection period, the inspector noted minor material deficiencies on several air operated valves.

These deficiencies were observed on valves in both safety and balance-of-plant applications.

Although short term operability of the valves was not in question, the inspector considered that these problems indicated a lack of attention to detail in maintenance involving air operated valves.

Specific deficiencies were discussed with the licensee and corrective action was initiated for each noted ite.2 Surveillance Observations 2.2.1 Routine Observations Inspectors observed portions of surveillances to verify proper calibration of test instrumentation, use of approved procedures, performance of work by qualified personnel, conformance to limiting conditions for operation (LCOs), and correct system restoration following testing.

The following surveillances were observed:

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Performance Test (PT)-1, "Rod Control System," revision 35, dated October 14, 1993, observed November 30, 1993

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PT-16M-T, "AuxiliaryFeedwater Turbine Pump - Monthly," revision 7, dated October 21, 1993, observed December 29, 1993 The inspector determined through observing this testing that operations and test personnel adhered to procedures, test results and equipment operating parameters met acceptance criteria, and redundant equipment was available for emergency operation.

Additionally, the inspector made the following observation:

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On December 21, 1993, the licensee conducted PT-2.1M, "Safety Injection System Monthly Test."

As a part of ttus test, flow meter FI-929A was used to measure the leakage rate of system boundary check valves.

The test also constituted an operational pressure acceptance test of the mechanical joints affected by replacement of this flow meter the previous week.

The system boundary check valves under test had historically been leak tight (zero leakage).

During this test, however, flow, as indicated by the new FI-929A, indicated that check valve leakage had developed.

Subsequent investigation revealed that the indicated flow on FI-929A was due to the presence of a set screw locking device, installed by the manufacturer to prevent meter damage during shipment.

The locking device was removed, and the boundary valves were again demonstrated to be leak tight.

The inspector assessed the cause of this problem to have been inattention to detail during installation of the replacement flow meter.

Beyond that, the fact that a problem with the flow meter existed could have been identified prior to its use in the performance test, in that the meter indicated flow even while it was isolated from the system.

2.3 Cold Weather Preparations (717I4)

The inspector reviewed the licensee's program to protect safety-related systems against the effects of extreme cold weathe In preparation for the onset of freezing conditions, the licensee completed Maintenance (M)

procedure M-1306.1, "Ginna Station, Maintenance Department, Winterizing Inspection Program," on October 27, 1993.

Procedural requirements included:

Inspection of heat trace circuits and piping insulation in identified plant areas susceptible to freezing.

Verification of anti-freeze protection for the Technical Support Center diesel, the security diesel, and the diesel fire pump.

. Inspection of windows, ventilation supply/exhaust vents, and unit fan heaters in various plant and outbuilding areas.

In carrying out this procedure, Preventive Maintenance (PM) Analysts coordinated the inspections, documented completion of the maintenance work orders resulting from the inspection, and informed operations supervision of the findings and status of any outstanding maintenance items.

Thirteen work orders were generated, prioritized, and assigned to the appropriate maintenance shops for action.

Through in-plant tours, the inspector concluded that the outstanding maintenance items identified in M-1306.1 are being appropriately addressed.

On December 23, 1993, the inspector accompanied an Auxiliary Operator (AO) as the AO conducted a periodic cold weather walkdown as required by Administrative (A) procedure A-54.4.1, "Cold Weather Walkdown Procedure."

A cold weather walkdown tour is performed once per week from November 1 through April 1, or with increased frequency, based on more severe weather, at the discretion of the Shift Supervisor.

A-54.4.1 identifies the plant areas and specific equipment that the AO verifies operable (by step sign-off) to assure that area temperatures remain greater than 45 degrees F. In addition to performing weekly cold weather walkdowns, AOs record temperatures of designated thermometers in potential cold areas during routine tours once each shift.

Should temperatures fall below 45 degrees F in these areas, AOs are directed to notify plant management for initiating corrective action.

By accompanying the AO, the inspector determined that all attributes of A-54.4.1 were satisfactorily addressed and minor deficiencies such as one inoperable heater were promptly reported to the maintenance department for disposition.

Cold weather preparations observed to be in place by the inspectors included installation of temporary plywood closures over intermediate building vent louvers located on the east wall of the building, securing various exhaust fans with louvers closed, and staging portable heaters for expeditious use.

Based on this review, the inspector concluded that the site freeze protection program is satisfactorily implemented, weH documented, and conscientiously monitored by knowledgeable personnel.

Corrective maintenance has been appropriately prioritized and has been timely for identified deficiencie I 3.0 PLANT SUPPORT (71707)

3.1 Radiological Controls 3.1.1 Routine Observations The inspectors periodically confirmed that radiation work permits were effectively implemented, dosimetry was correctly worn in controlled areas and dosimeter readings were accurately recorded, access to high radiation areas was adequately controlled, survey information was kept current, and postings and labeling were in compliance with regulatory requirements.

Through observations of ongoing activities and discussions with plant personnel, the inspectors concluded that the licensee's radiological controls were generally effective.

Additionally, the inspector made the following observation:

During radiographic e'xamination of piping in the turbine building basement, the inspector noted a weakness in'he established radiation area boundaries.

Radiation areas had been established in both the turbine building basement and middle level, using ropes and appropriate postings.

However, the inspector noted that an infrequently used access between the turbine building middle level and the basement had not been posted.

Using this access, it would have been possible for an individual, starting from outside of the radiation area in the middle level, to enter the radiation area in the basement without having passed through a barrier.

The inspector discussed this inadequacy with a health physics technician, and the deficiency was promptly corrected.

3.2 Security 3.2.1 Routine Observations During this inspection period, the inspectors verified that x-ray machines and metal and explosive detectors were operable, protected area and vital area barriers were well maintained, personnel were properly badged for unescorted or escorted access, and compensatory measures were implemented when necessary.

No unacceptable conditions were identifie 'I

'1 3.3 Fire Protection 3.3.1 Routine Observations The inspectors periodically verified the adequacy of combustible material controls and storage in safety-related areas of the plant, monitored transient fire loads, verified the operability of fire detection and suppression systems, assessed the condition of fire barriers, and verified the adequacy of required compensatory measures.

No discrepancies were noted.

4.0 Safety Assessment/Quality Verification 4.1 Periodic Reports Periodic reports submitted by the licensee pursuant to Technical Specification 6.9.1 were reviewed.

Inspectors verified that the reports contained information required by the NRC, that test results and/or supporting information were consistent with design predictions and performance specifications, and that reported information was accurate.

The following report was reviewed:

a Monthly Operating Report for November 1993 No unacceptable conditions were identified.

5.0 ADMINISTRATIVE(71707, 30702, 94600)

5.1 Deep Backshift Inspection During this inspection period, deep backshift inspections were conducted on December 4 and 12, 1993.

5.2 Exit Meetings At periodic intervals and at the conclusion of the inspection, meetings were held with senior station management to discuss the scope and findings of inspections.

The exit meeting for the current resident inspection report 50-244/93-24 was held on January 7, 1994.