IR 05000245/1986013
| ML20206M961 | |
| Person / Time | |
|---|---|
| Site: | Millstone  |
| Issue date: | 08/18/1986 |
| From: | Mccabe E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20206M955 | List: |
| References | |
| 50-245-86-13, 50-336-86-13, IEB-86-001, IEB-86-002, IEB-86-1, IEB-86-2, NUDOCS 8608260045 | |
| Download: ML20206M961 (10) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
Report Nos:
50-245/86-13; 50-336/86-13 Docket Nos:
50-245/50-336 License Nos:
Northeast Nuclear Energy Company Facility:
Millstone Nuclear Power Station, Waterford, Connecticut Inspection at: Millstone Units 1 & 2 Dates:
July 8, 1986 through August 18, 1986 Inspectors:
Theodore A. Rebelowski, Senior Resident Inspector Geoffrey E. Grant, Resident Inspector Approved By:
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&lI8/8/
E. C. McCabe, Chief, Reactor Projects Section 38 Date
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Summary:
50-245/86-13; 50-336/86-13 (July 8 to August 18, 1986)
Areas Inspected:- This inspection included routine NRC resident inspection (190 hours0.0022 days <br />0.0528 hours <br />3.141534e-4 weeks <br />7.2295e-5 months <br />) of plant operations, surveillance, maintenance, radiation protection, physical security, fire protection, and IE Bulletins.
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Results:
No unacceptable conditions were identified.
8608260045 860819 PDR ADOCK 05000245
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TABLE OF CONTENTS PAGE 1.
S umma ry o f Fac i l i ty Ac ti vi ti e s.......................................
2.
Review of Plant Operations - Units 1 & 2.............................
3.
Reactor Water Cleanup (RWCU) System Pipe Weld Failure - Unit 1.......
4.
Reactor Trip Due to Low Steam Generator Water Level - Unit 2.........
5.
New Fuel Receipt Inspection and Storage - Unit 2.....................
6.
Reporting Requirement Review.........................................
7.
Observation of Surveillance Testing..................................
7.1 Reactor Vessel High Pressure Scram Functional and Calibration Test...............................................
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7.2 Rod Block Monitor Functional Test...............................
8.
Observation of Maintenance...........................................
9.
Review of Licensee's Response to Selected Safety Concerns (TI 2515/77)
(Units 1 & 2).......
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10.
Plant Performance Indicators (TI 2515/80) (Units 1 & 2)..............
11.
IE Bulletin 86-02, 50R Differential Pressure Switches................
12.
IE Bulletin 86-01, Minimum Flow Logic Problems That Could Disable RHR
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Pumps..............................................................
13.
On-Site Safety Review Committee - Units 1 & 2........................
14.
Review of Periodic and Special Reports...............................
15.
Review of Licensee Event Reports (LERs)..............................
16.
Management Meetings..................................................
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DETAILS 1.
Summary of Facility Activities Unit 1 generally operated at full power during this report period.
A power reduction to 45% was made on July 16 in order to accomplish a Rod Pattern Ex-change, repair the
"B" condensate pump, locate and repair condenser and con-denser tube leaks and perform other corrective maintenance actions requiring a reduced power level.
Several times during the report period, power was re-duced to 80%-90% to support locating and repairing condenser tube leaks.
Other routine power reductions were required for thermal backwashing of main circulating water bays and testing of Main Steam Isolation Valves, turbine stop valves, turbine control valves and intercept valves.
A failure of a 1" pipe socket weld in the Reactor Water Cleanup System (RWCU) caused a one day isolation of the system and surface contamination of portions of the Reactor Building.
Unit 2 generally operated at full power during this report period except for an unplanned outage to locate and correct unidentified Reactor Coolant System (RCS) leakage.
The leak rate had been steadily increasing for the past month
i and had reached a value of approximately 0.9 gpm.
On August 12, during pre-parations for a power decrease to allow greater RCS inspection coverage inside containment, the unit tripped from 100% power due to low #1 Steam Generator level.
This commenced a four day outage to correct RCS leakage and perform other maintenance.
2.
Review of Plant Operations (Units 1 & 2)
The inspector observed plant operations during regular and back shift tours of the following areas:
Control Rooms Turbine Buildings Auxiliary Building Cable Vaults Enclosure Building Fence Line (Protected Area)
Reactor Building Intake Structure-Diesel Generator Rooms Gas Turbine Building Vital Switchgear Rooms Control room instruments were observed for correlation between channels, pro-per functioning, and conformance with Technical Specifications.
Alarm condi-tions in effect and alarms received in the control room were reviewed and
discussed with the operators.
Operator awareness and response to these con-ditions were reviewed. Operators were found cognizant of board and plant conditions.
Control room and shift manning was compared with Technical Specification requirements.
Posting and control of radiation, contaminated and high radiation areas were inspected.
Use of and compliance with Radiation Work Permits and use of required personnel monitoring devices were checked.
Plant housekeeping controls were observed including control of flammable and other hazardous materials.
During plant tours, logs and records were reviewed to ensure compliance with station procedures, to determine if entries were
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correctly made, and to verify correct communication of equipment status.
These records included various operating logs, turnover sheets, tagout and jumper logs, process computer printouts and Plant Information Reports.
The inspector observed selected actions concerning site security including per-sonnel monitoring, access control, placement of physical barriers, alarm station operations, and compensatory measures.
No unacceptable conditions were identified.
3.
Reactor Water Cleanup (RWCU) System Pipe Weld Failure - Unit 1 On July 23, 1986 the Unit 1 RWCU System experienced a pipe weld failure re-sulting in the release of approxinately 2200 gallons of reactor water to the Reactor Building.
The failure occurred at a weld connection to a 90 degree elbow on the 1" relief line for the
"C" regenerative heat exchanger.
The weld failure was 100% and resulted in complete separation of the relief valve from the pipe.
The first indication of the failure was a control room alarm indi-cating a high temperature in the RWCU heat exchanger room.
Upon investigation and report by a plant operator, the control room operator isolated the RWCU system.
This action prevented further release of reactor coolant through the separated relief line.
Three floors of the Reactor Building received surface i
contamination from the escaping reactor coolant and were subsequently decon-taminated.
No release outside of the Reactor Building occurred.
The weld was repaired and the RWCU system was returned to service in one day.
The licensee conducted an initial failure analysis by making visual and dye pene-trant inspections of the failed weld and similar RWCU system welds.
The lic-ensee believes the weld failure was fatigue induced due to inadequate piping support.
A broadened RWCU piping support analysis is underway.
That analysis will be considered during routine inspection. The inspector had no further
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questions in this area.
4.
Reactor Trip due to Low Steam Generator Water Level - Unit 2 On August 12, 1986 the Unit 2 reactor tripped from 100% power due to low level in #1 Steam Generator (SG-1).
Preparations were underway to reduce reactor power in order to support a containment entry for a Reactor Coolant System (RCS) leakage inspection.
The unidentified RCS leak rate had reached 0.9 gpm (Technical Specification limit is 1.0 gpm).
The low level in SG-1 was due to the loss of the "A" Steam Generator Feedwater Pump (SGFP).
The SGFP tripped when its associated auxiliary oil pump lost power upon loss of power to buses 22A and 228.
The auxiliary oil pump was in operation due to the low pressure output of the gear-driven (by the SGFP) pump.
Buses 22A and 22B were crosstied at the time due to performance of modifications to the bus 22A load side breaker.
(The modification includes a higher overcurrent trip setpoint.)
Initial licensee investigation of loss of power to buses 22A/228 points to
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overcurrent trip of the 22B load side breaker.
Licensee event investigation indicated that the overcurrent was caused by energizing pressurizer backup heaters to support forcing pressurizer spray for RCS boron equalization. The resident inspector reviewed post-trip computer printouts, data sheets, logs and records to verify the sequence of events and actions.
Normal post-trip actions were carried out with satisfactory results.
No deficiencies were
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identified during inspector review.
Long term correction of the overcurrent problem will be addressed by licensee modification of the breaker to provide i
a higher overcurrent trip.
The licensee has established short-term admini-t strative procedures to prevent recurrence of the bus loading condition that caused.the bus 22B breaker trip.
Correction of this non-safety-related breaker l
problem and of the gear-driven oil pump inadequacy will be reviewed during routine inspection.
5.
New Fuel Receipt Inspection and Storage-Unit 2
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The resident inspector observed licensee activities supporting the receipt and inspection of new fuel for the Unit 2 Cycle 8 refueling.
Observation commenced with attendance at the initial training of Quality Control and
Reactor Engineering personnel.
Training included coverage of the following topics:
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Overall new fuel receipt and inspection program.
Detailed discussion of applicable procedures.
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Demonstration of correct inspection techniques.
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Discussions of potential problems.
Discussion of acceptance / rejection criteria.
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Safety considerations.
Review of lessons learned during previous new fuel receipt inspections.
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Additional training for Operations and Maintenance personnel covered receipt inspection procedures.
The training material scope, depth and presentation were evaluated as very good.
The resident inspector reviewed approved plant procedures to determine tech-
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nical adequacy and completeness.
These included:
OP 2210A, New Fuel and CEA Receipt and Inspection.
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OP 2333-4, Spent Fuel Platform Crane Functional Test.
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OP 2303-5, New Fuel Elevator Functional Test.
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OP 2303-9, Spent Fuel Cask Crano Functional Test.
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OP 2303-11, New Fuel Inspection Machine Test.
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Documentation covering fuel receipt was reviewed including:
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New fuel shipment documentation.
New fuel receipt documentation.
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Bill of lading.
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Westinghouse quality assurance records accompanying each assembly.
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The inspector observed various aspects of the actual fuel receipt and inspec-j tion activities and reviewed records documenting completed inspections.
Ac-j tivities and records reviewed included:
Shipping vehicle receipt inspection which covered the initial exterior
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inspection of the shipping containers.
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Container receipt and inspection which covered the tamper seals, con-tainer bolts, shock indicators, labeling, contamination survey, and general interior inspection.
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Fuel assembly receipt and inspection which covered cleanliness, alignment, verification of critical dimensions, and correct configuration.
Material transfer documentation which covered the handling accountability
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of the assemblies.
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Examination of the New Fuel Storage Vault and arrangements to maintain assembly cleanliness.
The general operation of new fuel receipt and inspection was conducted in a satisfactory manner.
No deficient.ies were noted.
6.
Reporting Requirement Review Recently, the NRC Incident Response Branch (IRB) asked Region I to review classification of Millstone events apparently reported under 10 CFR 50.72 as
" general interest".
Also, during preparation of the current Systematic As-sessment of Licensee Performance (SALP) for Millstone, Units 1 and 2, licensee assignment of cause codes for equipment failure and overall event cause statements for Licensee Event Reports (LERs) were questioned.
These two issues, as documented in Millstone 3 Inspection Report 50-423/86-21, were inspected during the week of July 14, 1986.
The inspector found that the general interest classification was made incident to State of Connecticut requirements.
Because the NRC requires reporting of items reported to the State, these items were also reported to the NRC.
Also, LERs were found to be in need of improvement in regard to filling out of the failure cause block only for component failures, with the overall cause (which may be different)
being addressed in the LER text.
However, no safety inadequacies were found and the inspector had no further questions on these matters.
7.
Observation of Surveillance Testing The resident inspector observed several surveillance tests to determine whether performance was in accordance with approved procedures and Limiting Conditions for Operations, correct removal and restoration of equipment, ade-quate deficiency review and resolution, proper calibration and use of test instrumentation, personnel qualification and adequacy of procedure details.
7.1 Reactor Vessel High Pressure Scram Functional and Calibration Test On July 22, 1986 the inspector observed the conduct of SP 408B, Reactor Vessel High Pressure Scram Functional and Calibration Test, from both the control room and instrument locations (Reactor Building).
This sur-veillance checks the calibration setpoints and scram functions of the reactor vessel high pressure instrumentation.
Special inspector atten-tion was given to review of the surveillance procedure for technical
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specification conformance, adherence to administrative controls, obser-vation of the test, and review of completed test documentation.
Discus-sions with licensee personnel conducting the surveillance found adequate preparations and a high level of knowledge pertinent to the surveillance.
The inspector noted that the test pump used to supply hydrostatic pres-sure during the calibration process was faulty.
Leaking test pump in-ternals made the application of a steady pressure difficult.
This translated into an increased difficulty of technician reading of the setpoint pressures on the high accuracy gauge.
The inspector brought this condition to the attention of licensee supervision who promptly resolved the issue by replacing the test pump.
No other inadequacies were identified.
7.2 Rod Block Monitor Functional Test On July 23, 1986 the inspector observed the conduct of SP 410B, Rod Block Monitor Functional Test, from the control room.
The surveillance func-tionally checks the response to various test inputs in order to ensure proper actuation of rod withdrawal blocks.
Special inspector attention was given to review of the surveillance procedure, adherence to admini-strative controls, observation of the test, and review of the completed test document.
Discussions with licensee personnel conducting the test found an adequate level of knowledge pertinent to the surveillance.
The preparation for this surveillance appeared to be less than adequate.
Although the technicians understood the general intent and sequence of the test, they were using a revised surveillance procedure with which they appeared to be unfamiliar.
The procedure had not been " walked" or
" talked" through prior to its conduct.
This created confusion at several points during the surveillance.
The inspector brought the issue of in-adequate surveillance preparation to the attention of licensee supervi-sion.
Adequacy of preparation for surveillance is unresolved (50-245/
86-13-01) and will be followed-up on during subsequent inspection.
7.3 Additionally, the following surveillances were observed:
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SP 412A, Reactor Low Pressure Valve Permissive Functional and Cali-bration Test.
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SP 404B, Average Power Range Module Functional Test.
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SP 411B, Main Steam Line High Flow Functional and Calibration Test.
SP 408G, Turbine Control Valve Fast Closure Functional and Calibra-
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tion Test.
No deficiencies were identified during these tests.
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8.
Observation of Maintenance The inspector observed and reviewed various preventise and correc;ive main-tenance efforts in order to verify compliance with regulations, use of ad-ministrative and maintenance procedures, compliance with codes and standards, proper QA/QC involvement, use of bypass jumpers and safety tags, personnel protection and equipment alignment, and retest.
Activities inspectsd included:
Weld repair of the 1" pipe socket weld on the Reactor Water Cleanup
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System regenerative heat exchanger relief valve.
Repair of the "B" condensate pump.
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Appendix R fire protection modifications.
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Overhaul of Control Rod Drives.
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No deficiencies were noted.
9.
Review of Licensee's Response to Selected Safety Concerns (TI 2515/77)
(Units 1 and 2)
The inspector reviewed licensee actions and responses on a selected sample of safety concerns.
These issues had been previously identified in IE Bul-letins, Circulars and Information Notices.
Areas covered included:
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Feedwater coolaat injection (FWCI) system reliat-ility.
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Heat exchanger biofouling.
Natural circulation cooldown.
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The licensee has addressed these matters.
No problem areas or unacceptable conditions were identified by NRC inspection.
10.
Plant Performance Indicators (TI 2515/80) (Units 1 & 2)
The inspector reviewed and correlated a variety of licensee operating para-meters as part of the performance indicator program.
Areas included in the review were:
Unplanned shutdowns.
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Control room alarms.
QA audits.
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Maintenance backlog.
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Enforcement actions.
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Personnel turnover.
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Personnel experience.
It was found that the licensee does not have a consolidated system for real-time tracking of outstanding QA audit items.
No violation of NRC requirements was identified in this case.
The potential for failure to complete QA audit action items will be reviewed further during routine inspection and considered during NRC assessment of licensee performance.
11.
IE Bulletin 86-02, SOR Differential Pressure Switches (Units 1 and 2)
This Bulletin asked the licensee to determine whether Series 102 or 103 dif-ferential pressure switches supplied by SOR, Inc. vere installed as electrical equipment important to safety.
IR 50-245/86-09; 50-336/86-09 addressed the licensee's usage of these switch models (nc suspect switches were identified as t.eing in use).
The resident inspector reviewed the lfcensee's response to IE Bulletin 86-02 in order to ascertain its adequacy and correctness.
The licensee's response included the information required to be reported, was technically correct and was made within the required time period.
No discre-pancies were noted.
12.
IE Bulletin 86-01, Minimum Flow Logic Problems That Could Disable RHR Pumps (Unit 1)
This Bulletin informed licensees of problems with the minimum flow logic in BWR ECCS systems for which a single failure could disable all RHR pumps.
The licensee was asked to respond indicating whether this single failure vulner-ability existed and corrective actions if it did exist.
The licensee's re-sponse indicated that this problem was nonexistent at Millstone Unit 1.
The resident inspector independently researched the applicability of the Bulletin to Unit 1 through use of the FSAR, piping and instrumentation diagrams, and system descriptions.
The inspection verified the accuracy and completeness of the licensee's response.
Additionally, the response was made within the specified timeframe.
No deficiencies were noted.
13.
On-Site Safety Review Committee The resident inspector attended meetings of the Unit 1 Plant Operations Review Committee (PORC) on July 10, 15, 16 and 22 and the Unit 2 PORC on July 9.
The inspector found that the conduct of the meetings met the requirements of Technical Specifications for committee membership, meeting frequency, and fulfillment of responsibilities.
The presentations elicited active question-ing and discussions.
Committee members presented an informed and critical overview of plant design and operations.
Individual member's opinions were encouraged.
No deficiencies in PORC performance were observed.
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14.
Review of Periodic and Special Reports Upon receipt, periodic and special reports submitted pursuant to Technical Specifications were reviewed.
This review verified that the reported infor-mation was valid and included the NRC required data; that test results and supporting information were consistent with design predictions and performance specifications; and that planned corrective actions were adequate for resolu-tion of the problem.
The inspector also ascertained whether any reported in-formation should be classified as an abnormal occurrence.
The following re-ports were reviewed:
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Monthly Operating Report 86-06 for plant operations from June 1-30, 1986
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(Unit 2).
Monthly Operating Report for plant operations from June 1-30, 1986 (Unit
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No unacceptable conditions were identified.
15.
Review of Licensee Event Reports (LERs)
LERs recently submitted were reviewed.
The inspector assessed LER accuracy, whether further information was required, if there were generic implications, adequacy of corrective actions, and compliance with the reporting requirements of 10 CFR 50.73.
Selected corrective actions were checked for thoroughness and implementation.
LERs reviewed included:
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85-020-01 Reactor Scram while performing SP408P (Unit 1) (Follow-up)
85-034-01 Control Rod Failure to Scram (Unit 1) (Follow-up)
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No unacceptable conditions were identified.
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Management Meetings During this inspection, periodic meetings were held with senior plant manage-ment to discuss inspection content and findings.
A summary of the findings was discussed with the licensee at the conclusion of the report period.
No proprietary information was identified as being in the inspection coverage.
No written material was provided to the licensee by the inspector.
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