IR 05000255/1996018
| ML18066A850 | |
| Person / Time | |
|---|---|
| Site: | Palisades  |
| Issue date: | 01/17/1997 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML18066A849 | List: |
| References | |
| 50-255-96-18, NUDOCS 9701300003 | |
| Download: ML18066A850 (6) | |
Text
- U.S. NUCLEAR REGULATORY COMMISSION Docket No.:
License No.:
Report No.:
Licensee:
Facility:
Location:
Dates:
Inspectors:
Approved by:
Inspection Summary REGION Ill 50-255 DPR-20 50-255/9601 S(DRS)
Consumers Power Company 212 West Michigan Avenue Jackson, Ml 49201 Palisades Nuclear Generating Plant 27780 Blue Star Memorial Highway Covert, Ml 49043-9530 November 18, 1996 through January 6, 1997 R. Lerch, Reactor Inspector M.A. Ring, Chief Lead Engineers Branch Division of Reactor Safety The inspector observed the engineering staff responding to the test failures of several installed molded case DC circuit breakers. The licensee decided to replace the breakers; an unresolved item was identified regarding these breaker failures. The loss of oil from reactor coolant pumps and several inspection follow-up items were also reviewed. No *
violations or deviations were identifie PDR ADOCK 05000255 G
- Report Details Ill. Engineering E1 Conduct of Engineering E1.1 D. C. Molded Case Circuit Breakers Inspection Scope (92903)
On November 17, 1996, with the reactor shut down, licensee testing results identified four of four molded case DC panel distribution breakers that failed to trip during overcurrent test conditions. The inspector reviewed licensee actions in response to the identified test result Observations and Findings Based on the 100% failure rate of tested molded case circuit breakers, the licensee concluded that a significant number of installed D.C. breakers wculd probably fail to trip on demand such that the plant was outside its design basis. A report was made to the NRC in accordance with 10 CFR 50.72. The tested breakers were Westinghouse model FB2270ML breakers; however, there were a total of 72 DC panel distribution breakers (of various Westinghouse models) which perform similar functions in the plant. The licensee issued condition report C-PAL-96-1473 and replaced all the active breakers. A review of the work history record identified that only 7 of the breakers had routine maintenance performed through the periodic and predetermined activity control (PPACl program. The licensee staff, and a conditio report written in response to Information Notice 93-63, indicated that minimal to no maintenance work had been performed on the other breakers. The licensee issued licensee event report (LERl 255/96013 which committed to testing the removed breakers, and submitting a supplemental LE Other problems encountered by the licensee included the identification that equipment lists were not accurate resulting in the need to walkdown the breaker panels to identify the installed breaker models. The licensee's staff also reported that the design bases for breaker selection (magnetic only vs. magnetic and thermal trips) were not retrievabl Conclusions The inspector concluded that the licensee's investigation into the circumstances, cause and consequences related to DC molded case* circuit breaker failures was proceeding in an appropriately thorough and rigorous manner, but many questions still remained unanswered. The issue of molded case circuit breaker failures and related problems is considered an unresolved item (255/96018-01) pending completion of the licensee's investigation and determination of the extent and significance of the problem.
- E1.2 Primary Coolant Pump Oil Leakage Inspection Scope (92703!
In an earlier inspection, see Inspection Report 255/96012, the inspector reviewed the*general condition of the primary coolant pump oil collection system and related problems including oil leakage through the pump motor as discussed in LER 95-01 The inspector continued the review of this issue during this inspectio Observations and Findings The system engineer had been measuring motor oil consumption and had identified that several gallons of oil could not be accounted for in condition report C-PAL-96-.
0724. The inspector walked down the area around the P-50C primary coolant pump inside the containment. The oil collection system on top of the pump was disassembled for work, and the area was generally in good order, but there was a slippery oil film that could be felt on surfaces near the motor. The licensee had
.
evaluated the loss of oil and concluded that it was leaking through the motor and being sprayed or atomized into the surrounding area. This resulted in slight build up of oil on surfaces around the pumps. In discussions with NRR, it was concluded that this loss of oil did not represent a significant hazard at this time. The licensee was trending the oil consumption and evaluating pump motor maintenance option Conclusions While problems continued with oil leakage from the primary coolant pump, the inspector concluded the licensee was appropriately monitoring the condition and developing corrective actions. The inspector had no further concerns with this issue at this tim ES Miscellaneous Engineering Issues (92903 and 92702)
E Inspection follow-up item. 255/94014-39: the roles and responsibilities of the two onsite engineering organizations and the interfaces between them were not well defined. The licensee implemented plans from the Palisades Process Enhancement Program (PPEP) to train the staff on mam;igement expectations and clarify procedures on organizational objectives and tasks. Subsequently, the engineering functions were reorganized twice and the licensee implemented management tools to continue critical self assessment of role fulfillment. The realignment of system engineers reduced their tasks and resulted in improved support to the plant. This item is close E Inspection follow-up item, 255/94014-40: weak plant support from engineerin The licensee had taken extensive action to improve the performance of engineering including reorganization, physical relocation of engineering offices inside the protected area, and training. In addition, the licensee's PPEP developed additional plans to improve engineering. Some of the activities which were improved included Departmental Management Action Plans, time and work management systems, training programs, and the corrective action process. These and other changes
- have brought engineering into a closer working relationship with the other departments and improved engineering performance. This item is close E Inspection follow-up Item. 255/94014-44: lack of preventive maintenance for emergency diesel generator (EOG) voltage regulat~rs. Review by the licensee, including testing by the voltage regulator manufacturer, identified that the failure was related to age after 22 years of service. The specific cause was loosened solder connections which had shown up during surveillance testing of the EOG. In response, the licensee had planned voltage regulator bench testing on a 10 year cycle using the PPAC program. In addition, the threshold for problem identification had been lowered in recent years and root cause analysis processes improved such that should this problem occur again, it would be identified and corrected earlier than the 20 months cited by the Diagnostic Team Inspection. This item is close E Inspection follow-up item. 255/96014-52: engineering Was often slow to evaluate problems and did not recognize the safety significance and effectively resolve problems. Improvements developed through the licensee's PPEP addressed this item. The actions taken included revision of the corrective action program to improve prioritization and operability determination processes, engineering reorganization which includes subsequent reorganizations to improve support to the plant, and improved management tracking of work items. As a result, engineering effectiveness and timeliness in resolving issues was improved. This item is close E Inspection follow-up item. 255/94014-57: design, implementation and control of plant modifications were sometimes deficient which occasionally resulted in modifications that did not achieve the intended result. The licensee instituted a multi-disciplined team review for complex modifications, revised the plant modifications procedures to clarify and improve them, and set training standards for engineers performing modifications. This item is close E Inspection follow-up item. 255/94014-59: uncontrolled mounting of equipment on safety-related masonry block walls. The licensee perform~d a walkdown of all of the safety-related block walls and four individual wall calculations were identified as needed. The licensee completed these calculations. Walls were also examined for appropriate labeling on wall loading/modification restrictions. The posting of walls was completed as of June 26, 1996. The controlling document, "Specification C-265," was revised January 24, 1995. This item is close ES. 7 Inspection follow-up item. 255/95014-03: environmental qualification (EQ) of Raychem splices on Rosemount transmitter leads. These splices were all replaced with a design which incorporated an additional boot seal on the field cable. This eliminated reliance on the field cable jacket for a moisture seal. This item is close V. Management Meetings X1 Exit Meeting Summary The inspectors presented the inspection results to members of licensee management at the conclusion of the inspection on November 21. 1996. Additional teleconferences were
- conducted in December 1996, to discuss the loss of oil from reactor coolant pumps. A final telephone exit was held on January 6, 1997. No proprietary information was identified in the exit material LIST OF PERSONS CONT ACTED Licensee D. Fadel, System Engineering Manager B. Gerling, Design Engineering Deputy Manager R. Hamm, System Engineering Supervisor K. Powers, Nuclear Services General Manager R. Smedley, Licensing Projects Supervisor R. Vincent, Licensing Supervisor INSPECTION PROCEDURES USED IP 37551:
IP 92903:
Onsite Engineering Follow-up - Engineering ITEMS OPENED AND CLOSED Opened 50-255/96018-01 URI Failures in DC molded case circuit breakers Closed 50-255/94014-39 IFI 50-255/94014-40 IFI 50-255/94014-44 IFI 50-255/96014-52 IFI 50-255/94014-5 7 IFI 50-255/94014-59 IFI 50-255/95014-03 IFI The roles and responsibilities of the two onsite engineering organizations ~nd the interfaces between them were not well define Weak plant support form engineering Lack of preventive maintenance* for emergency diesel generator voltage regulators
- Engineering was often slow to evaluate problems and did not recognize the safety significance and effectively resolve problem Design, implementation and control of plant modifications were sometimes deficient which occasionally resulted in modifications that did not achieve the* intended resul Uncontrolled mounting of equipment on safety-related masonry block walls Raychem splice shim material was not EO qualified
'
~*
CFR CR DET DRS EDG EO IFI IP IR LER NPAD NRC NRR PDR PPAC PPEP LIST OF ACRONYMS USED Code of Federal Regulations Condition Report Diagnostic Evaluation Team Division of Reactor Safety Emergency Diesel Generator Environmentally Qualified Inspection Follow-up Item Inspection Procedure
Inspection Report
Licensee Event Report
Nuclear Performance Assessment Department
Nuclear Regulatory Commission
Office of Nuclear Reactor Regulation
Public Document Room
Periodic and Predetermined Activity Control
Palisades Performance Enhancement Program
6