IR 05000272/1987018
| ML18093A310 | |
| Person / Time | |
|---|---|
| Site: | Salem  |
| Issue date: | 08/11/1987 |
| From: | Swetland P NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML18093A309 | List: |
| References | |
| 50-272-87-18, 50-311-87-20, NUDOCS 8708200119 | |
| Download: ML18093A310 (23) | |
Text
- Report No Docket No License No Licensee:
U. S. NUCLEAR REGULATORY COMMISSION
REGION I
50-272/87-18 50-311/87-20 50-272 50-311 DPR-70 DPR-75 Public Service Electric and Gas Company 80 Park Plaza Newark, New Jersey 07101 Facility Name:
Salem Nuclear Generating Station - Units 1 and 2 Inspection At:
Hancocks Bridge, New Jersey Inspection Conducted:
June 15, 1987 - June 19, 1987 Inspectors:
Approved by:
T. J. Kenny, Sen}or Resident Inspector, Team Leader L. J. Norrholm, Section Chief, SIB, ORIS, NRR W. M. Hill, Senior Reactor Engineer, N~R J. W. Chung, Lead Reactor Engineer, Region I A. J. Szczepaniec, Reactor Engineer, Region II P. D. Swetland, Chief, Reactor Projects Section No. 2B, Projects Branch N ~ DRP Inspection Summary:
~l/({n
' da e Inspections on June 15, 1987 -.June 19, 1987 (Combined Report Numbers 50-272/87-18 and 50-311/87-20)
Areas Inspected:
Feedwater and condensate systems, including maintenance, survet]lance, design changes, operations and management overvie The inspection involved 192 inspector hours by the NRC inspectors.
8708200119*870813 PDR ADOCK 05000272 G
Results:
The inspection team concluded that the licensee has successfully reduced the previously high number of Balance of Plant (BOP) related reactor trip Management commitment in the form of manpower, expenditures, engineering, and preventive and corrective maintenance was eviden Strengths identified included significant, multi-disciplined review and implementation groups focused on reactor trip reductio Weaknesses included minor procedure and system discrepancies identified by the team.
- DETAILS Persons Contacted Within this report period, interviews were conducted with members of licensee management and staff as necessary to support the inspection activit The personnel in attendance at the entrance and exit interview are listed in Appendix.
History Unit 1 came on line in December 1976 and Unit 2 came on line in May 198 As can be seen by the table in Appendix 11 B 11, feedwater,related reactor trips were numerous throughout the operating history of Salem statio The total reactor trips for both units at Salem is 260, with 118 trips being related to the feedwater syste According to the Westinghouse Owners Group (WOG) studies, this is an average ratio of trips th~t are feedwatef related among Westinghous~ plant After an analysis of the types of reactor trips that are attributable to feedwater, two major, or above the average, subsets of this type of reactor trip can be identified; operator related, and feed pump relate Operator related reactor trips, especially during the start up of the units, are directly attributable, for the most part, to the complex system design and operator inexperience at operating the syste The design of the steam dump system (described in section 5) did not lend it~elf to a smooth transition while placing the turbine on lin This coupled with manual control feedwater bypass valves led to the majority of operator induced feedwater trip Feed pump related reactor trips are due mainly to a low suction pressure condition (described in section 5) tripping the feed pump This problem has occurred partly due to the design of the condensate system and also as a result of cascading transients in the heater drain syste With the correction of the aforemention.ed problems by an improved steam dump system, automatic feedwater regulating bypass valves, and the addition of higher capacity condensate pumps, feed system related trips have been reduced and the recent (since 1985) reactor trips-appear to be cause~
mainly by random equipment failur The reactor trips currently being experienced in the feedwater system are also more compound, in that they are multi-symptom relate For example, a feedwater or condensate system transient, brought about by an equipment failure, is compounded by an operator error while responding to the problem resulting in a reactor tri The team also identified that recently the operators, by appropriate and immediate response, have prevented plant trips following feed pump trips at high power level This action was not regularly achieved during earlier plant operation Improved operator training and performance in the plant and feedwater system operation was noted after the start up of
_J
- the plant specific simulato Modifications in operating procedures and lineups for the turbine control system have also enhanced the ability of the operators to recover from plant transients that in the past would have t~ipped the uni *
Other modifications to the instrumentation system, feed regulating valves, feedwater pumps and control oil system, have also contributed to an improved operation of the feed and condensate system.0 Operations 3.1 System (Valve) Lineups The status and control of valves are maintained on the Tagging Request and Inquiry System (TRIS), a computer database syste This system was developed to avoid the inadvertent mispositioning of com-ponents (valve, breaker, disconnects, etc.) during component alignment for specific modes of operation and for safety tagging operation The inspector reviewed a valve alignment report printout from the TRIS system for operation of Unit 2 feed and condensate systems in mode The valve identification and positions were consistent with those-listed on the Unit 2 steam generator feed and condensate drawing (DWG) 205302, (Revision 28).
The ins.pector also reviewed the Unit 1 steam generator feed and condensate DWG, 205202 (Revision 32).
The inspector noted a labeling error on sheet 3 of 3 for this drawin Both feed pumps were labeled at the pump discharge as 11 No. 12 ST GEN. FEED PUMP.
One should have been identified as *the No. 11 steam generator feed pump (SGFP).
The inspector discussed this with a member of the QA organization, who indicated that it would be correcte No other errors were detected on the drawings or valve lineup The inspector also reviewed operating procedures for the feedwater and condensate system Interviews with the operators indicated a good knowledge of systems and operating procedures on the part of the operator However, the inspector observed that certain plan changes (condensate pump upgrades) were not reflected in operating_
procedure Condensate pump parameters, in the current procedure while conservativ~, do not reflect the actual parameters of the new pump This proble~ was identified to the licensee fof correttive actio Further discussion with licensee management indicated other minor BOP procedure discrepancies for which licensee review and corrective action was appropriat.2 Walkdown The inspector cooducted a walkdown of the feed and condensate systems (partial) for Unit 2 with particular attention paid to the following i terns:
- valve positions maintenance activities cleanliness and preservation*
component conditions labels and tags The inspector noted the following observations:. The valves were in their expected condition for a plant operating at power and although no valve maintenance was observed, there were indications that an active program was ongoing re1ative to steam leak repair On1y one steam leak was observed on a heater drain valve near the condensate pump There were some valves with lagging removed which indic~ted that steam leaks had recently been repaire All of the feed and condensate valves examined by the inspector were*
labele The main steam, feed, condensate and other system piping in the turbine building had been labeled with colored tape to indicate the system, line number, and direction of flo Metal identification tags were attached to all of the feed and condensate valves which the inspector examine Most of the system labeling had been completed in the last yea On several Limitorque valves, stem covers were missin One pressure gage on No. 2 lube oil purifier was broke With the exception of these deficiencies, the feed and condensate systems for Unit 2 appeared to be in good conditio These items wer-e discussed with the license There was also cleaning and preservation (painting) in progres The results of the walkdown indicated that increased management attention to the balance of plant was eviden.3 Operator Information The inspector reviewed several Operation Department's 11 Newsletters.
They provided pertinent information to the operators on a daily basi The newsletters generally contained the following general types of information:
Unit 1 Standing Orders Unit 2 Standing Orders Standing Orders common to both units Unit 1 Status Unit 2 Status Notices Review of Past Notices Procedural Changes Safety Concerns General Interest
- Notices usually described recent incidents which have occurred in the industry and were of interest to the operating staf Past notices contain similar information of interes The Operations Department has also established 11 Information Directives 11 (IDs) to disseminate operating information to designated personne They are used to transmit items pf information, signifi-cant LERs, NRC Bulletins, introduce new or revised procedures, inform the shift of temporary or permanent changes to operating parameters or practices or any other functions deemed necessary by the Operations Manage The NRC inspector reviewed several IDs to ensure that information was being disseminated in a timely manne Another system established to provide information to the operators is the Technical Department Engineering Memo (TDEM).
These are used primarily to convey to various departments information regarding operation, maintenance, or other site activities derived from engineering studies or vendor field instruction The TDEMs were originated based on engineering review of the following types of documents:
Operational history review (pump flow, pump vibration data, etc.)
System (component) failures Vendor manual review, updates Technical specification/license changes NRC/regulatory bulletins Industry related experience (INPO)
TDEMs also include any action that is required as a result of an engineering revie The inspector reviewed several TDEMs to confirm that the information provided or requested was sufficiently clear to communicate the appropriate information or initiate the desired actio Distribution verification for both IDs and TDEMs is accomplished by an initialed distribution sign-off shee During refueling outages, summaries were prepared for those design changes which are planned for that outag These summaries listed the system, the design change number, and the drawings affecte A brief description of the change was given including figures where appropriat Changes to valve lineups and procedures were also discusse In addition, formal operator training covering all new design changes is conducted prior to start-up from each refueling outag *
Based on' review of these programs, the inspector concluded the lic~nsee's programs cover both safety-related and BOP topics, and are adequate to disseminate information to the licensee personne,*
)
3.4 Vendor Technical Manual The inspector reviewed controlled vendor technical manuals for the following equipment:
Component Steam Generator Feed Pumps SG Feed Pump Turbines Condensate Pumps Condensate Pump Motors Vendor Worthington Transamerica Delaval Ingerso.11-Rand Electric Mach. Mfr. C The inspector confirmed that the vendors* recommendations for oper-ation of the above equipment ~ere consistent with the license~'s operating procedure The precautions, safety notes, operating limits and other parameters were included in the procedure No problems were identified with incorporation of vendor technical information into station procedures for the identified BOP equipmen.5 LER Review The inspector reviewed several recently submitted LERs that detailed reactor trips as a result of events initiated within the balance of plan Those reactor trips initiated by the secondary plant and attributed to operator or personnel error were frequently accompanied by the following factors:
passive component failures off normal conditions unusual tests or operating procedures restriction in BOP flexibility The inspector expressed his concern that reactor ~rips and safety system challenges seem to occur when accompanied by one or several of the above conditions which should be emphasized to the operators when any of the above conditions are anticipate The licensee acknowledged the inspector 1s concer No violations were identifie.0 Maintenance Activities 4.1 Corrective Maintenance Program Site activities with regard to corrective maintenance are described in the station administrative and maintenance procedure Activities associated with mechanical, electrical and I&C maintenance utilize separate control procedure The scope of this inspection was limited to maintenance procedures related to the feedwater and condensate syste **.. *
. The inspector selected certain procedures, as described below, for detailed revie Procedure M-6F provides guidelines and detailed instructions for the repair, overhaul, inspection, and reassembly of the Steam Generator Feed Pump (SGFP).
Procedure M-24 includes eight subsections for feed and condensate systems as well as heater bypass control valve inspection guideline Procedure M-240 delineates various instructions for the SGF~ recirculation control valve,.
including removal, installation, and disassembl Based on the review of these procedures, the inspector determined that the maintenance procedural steps were appropriately highlighted in some areas to avoid a safety system c*hallenge caused by equipment malfunction or failures in the feedwater syste The inspector also noted that design and facility modifications for the feedwater system or *related support systems were evaluated in accordance with the 10 CFR 50.59 requirements. In fact 1 the maintenance program for the feedwater system was treated the same as a safety-related system, and the tasks were routinely performed by personnel qualified to perform work on safety-related system A computerized Maintenance Information Retrieval System is currently operationa This program provides automated material history and maintenance planning information for all plant equipmen The licensee is continuing to make refinements and intends to consolidate all maintenance activities into one centralized information retrieval system which will include the station work order.1.1 Corrective Measures to Improve Equipment Failures Equipment failures in the feedwater system were routinely evaluated and their results were incorporated into the corrective and preventive maintenance program Such evaluation results aided in providing an input into the possible design changes or modification The following corrective measures to minimize valve packing leaks and to improve system performance were reviewed:
An orifice was installed in the moisture separator reheaters to improve system stability and performanc Special leak-sealing chemicals were sprayed over the condenser joints to reduce the air inleakage to the main condense The feedwater regulating valves were repacked with Chesterton live-loaded packin This has reduced valve packing le_aks and improved system reliabilit *"\\,:..1
,,
9, Three steps of preventive ahd corrective measure~ were being-applied td eliminate water accumulation in the SGFP control oil syste A weekly surveillanc~ check for water accumulation in the control oil sump was implemented, a design change was implemented to upgrade the moisture separator system and reroute the moisture separator piping in order to draw a suction on the bottom of the control oil sump, and a Design Change Request (OCR) has been initiated to install separator filters at the inlet of the SGFP governo In addition, a SGFP turbine drain modification~ OCR No. 25M-00094, has been scheduled to be completed during the next outage.-
4.1:2 Post~Trip Maintenance Activities The post-trip work activities covering the period between 1982 and 1987 were reviewed (see Appendix D).
Since 1982 a total of 27 feedwater system induced reactor trips were experiented for Salem Units 1 and Seven of the 27 trips were related to feedwater regulating valves (BF-19s), 12 of 27 trips due to SGFP problems, 3 of 27 due to instrumentation ~nd logic problem Five others could not be categorize Within the scope of this review, the inspector determined that adequate corrective measures were taken, and the root-cause analysis of the prbblems were properly ~V?lua~ed and assesse The preventive measures -and the -immediate actions taken were accomplished in a timely manne The inspector noted that the licensee was not able to locate some of the completed work orders, and the status of some work orders was unknow The licensee representative stated that because of recent reorganization of the maintenance department and ongoing implementation of MMIS computerized system, some work orders were filed out 6f sequence and it would take a loriger time to locate the In the interest of time and the amount of work orders reviewed the inspector did not pursue the work orders in questio.2 Preventive Maintenance Program The ~tatio~ preventive maintenance program is delineated in procedure TD 8, Preventive Maintenance, Revision 0, and prescribes the managers responsibilities as well as periodic actions, and predictive methods to be utilized by station personnel to determine and schedule preventive maintenanc Procedure TI 14, Vendcir Manual Review Program, Revision *o, provides instructions related to the vendor manual review progra Instrument calibration activities are conducted in accordance with the station I&C calibration procedure The inspector reviewe general instrument calibration pr~cedure 1 IC-1.4.003, and channel sensor calibration procedures, 2PD-2.9~109 and 2PD-2.9.110, for the steam generator feedwater pumps and steam dump pressure sensors respectivel The associated calibration data sheets were also reviewe The pressure sensor for No. 21 condensate pump discharge -
flow was calibrated on February 13, 198 The associated flow transmitter was calibrated on February 14, 198 Within the scope of this review, the inspector concluded that the preventive maintenance procedures with regard to the feedwater system were
. consistent with the other safety-related system procedures, and met the guidance specified in ANSI Nl8. 7-1976 and Regulatory Guide 1.3.
.
The licensee also instituted a Machine Condition Monitoring Program to monitor component performance, and predict required maintenance prior to failur This will allow the licensee to schedule maintenance during available plant load reductions, and prevent trips related to component failur The heater drain pump and condensate pump are monitored for excessive vibration, and spectral frequency analyses are performed, and the results are applied to the pump predictive maintenance prpgra An Equ'ipment Performance and Reliability_ Trending Program has been instituted, in which oxygen content in the condensate system and condenser air inleakage are trended.* The inleakage trending program resulted in a preventive measure to reduce the inleakage by spraying the condenser penetrations with a special chemical, which increased the vacuum from 1.7 inch-Hg to 1.2 inch-H A pump bearing temperature trending program led to a minor design change request (DCR), No. ISM-0280, which increased the bearing temperature alarm setpoint An excessive number of alarms had been actuated for the condensate pump, unnecessarily diverting the operator's attentio As a part of the reactor trip reduction program fof critical components, a program has been initiated addressing INPO standards for contractor bid specification The objective is to provide detailed instructions and specifications for future contract bidders, and includes the following items:
Reliability-Centered Maintenance (RCM) tasks Spare parts controls for the preventive maintenance Monitoring standards and performance trending systems
..._,
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In addition, a quote document, QUOTE NO. 87015, was released on January 19, 1987 to solicit bidders to develop a Level I Probabilistic Risk Assessment (PRA) mode The objective was to utilize the PRA study to identify the risk and weaknesses of the plant, and incorporate the study results into the maintenance progra Even prior to the PRA bid solicitation from vendors, the li~ensee MMIS project prioritized the Salem plant systems by rank order as determined by employing the Value Oriented Decision Analysis Process (VODAP).
The VODAP ranks the plant systems* by assessing the tangible and intangible parameters regarding system operation and reliability. Therefore, a higher ranked system offers a better return in terms of operating and maintenance cost In the VODAP rank order (see Appendix D), the steam generator feedwater and condensate system ranks seventh, and the feedwater pump lube oil system ranks twentiet Other safety-related systems such as reactor coolant, reactor protection, vital electric power and service water ranked higher than feedwater syste The licensee evaluated failure history of the systems from the corrective maintenance work orders, and performed a time series analysi The study further subdivided and analyzed the component level for the failure cause and failure modes, and specific recommendations and maintenance tasks were develope Some of the recommended maintenance tasks for the Main Feedwater and Condensate System are as follows:
Equipment/Component Valves 11 thru 14 BF40 21 thru 24 BF40 13, 23 CN22 12, 21 CN27 11, 12, 21, 22 CN8 21, 22 CN22 12 CN36 21 CN27 Frequency Every 3 years (3Y)
3Y *
3Y 11 and 12 Feedwater Pump SY 21 and 22 Feedwater Pump Pump Suction Line Flanges Pump/Turbine Drain Line Flanges Turbine Gland Seal Flanges*
Maintenance Task Calibrate electric position transmitter Inspect, lubricate exercise positioner linkage Inspect and adjust switches as necessary Inspect flange, tighten flange bolts to specification or replace gasket as require Equipment/Component Frequency 11, 12, 21 and 22 Feedwater 3Y Pump Turning Gear Engagement Mechanism Mechanical 11 Pump/Turbine Lube Oil Piping System 12 Pump/Turbine Lube Oil Piping System.
21 Pump/Turbine Lube Oil Piping System 22 Pump/Turbine Lube Oi Piping System 1 Lube Oil Separator 2 Lube Oil Separator Instruments 1, 2 PD-2319 1, 2 PD-2340 1, 2 PD-2765 1, 2 PD-2766 1, 2 PL-2901 1, 2 PL-2902 1, 2 PL-2176 SY 4Y 2Y 2Y 2Y Maintenance Task Inspect/overhaul solenoid valve.*
Test limit switch actuation, adjust as necessar Exercise and lubricate engagement component Inspect all flanges and joints for
- 1 ea k Torque flange bolts or renew sealing compound/gaskets, as require Disass~mble, inspect and* overhaul, ai necessar Calibrate Calibrate Calibrate In conclusion, the inspector determined that the above innovative program should enhance both the preventive and corrective maintenance tasks, and that the availability of the feedwater system and the challenges to the safety-related systems would be improved should such a program reach full implementatio FurthermQre, the inspector noted that activities related to the feedwater and condensate system were treated the same as those for the safety-related systems including use of procedures, documentation of work, and quality control inspectio,_
4.3 Inservice Inspection Program The Inservice Inspection (!SI) program is limited to those valves associated with the containment isolation specified in technical specifications, which included feedwater regulating bypass valves (BF-40s) and feedwater regulating valves (BF-19s).
Inservice testing for these technical specification valves was performed using -
procedure, SP(0)4.0.5-V-MS-5, Revision 0, Inservice Testing - Valves Main Steam and Boiler Fee The !SI records were reviewed as follows:
Valves Bypass valve BF-40 Stop Check valve BF-22 Regulating valve BF-19 Date Performed 9/15/86 9/15/86 9/15/86 In a letter dated June 4, 1987, SPE-87-0135, the licensee instituted an inspection procedure to meet the anticipated requirements for inspection of high energy, carbon steel piping systems by Institute of Nuclear Power Operation (INPO) and USNR The initiative was a coordinated effort to inspect single phase erosion/corrosion of the high energy piping syste The licensee also ~onducted ultrasonic examinations of selected feedwater piping systems in conjunction with their response to the feedwater line rupture event at Surr The examination results were documented in a summary report dated February 2, 198 Ba3ed on the above reviews, the inspector determined that no unacceptable conditions were idehtifie Procurement of Replacement Parts The station replacement and spare parts are controlled by a computerized Materials Management System (MMS), and they are classified into approximately 1300 QA classifications by requirements and function There were only 20 exception items listed in the attachment 5, QA Exception List, VPN-PRP-01, Revision Several procurement records were reviewed to verify that the replacement parts for the feedwater system were either equivalent to or better in quality than the original part The following purchase orders were reviewed:
Item Purchase Order Date Comments BF-i9 FWS Regulating, 918437 3/29/84 same as Vulcan 14 11 Globe Valve original gasket 917893 3/27/84 same as original
Item Purchase Order Date Comments BF-19 Vulcan Globe 919715 4/10/84 same as packing original 939556 3/27/85 same as original 117520 11/18/85 same as original SGFP Worthington Pump 943267 6/13/85 same as shaft original SGFP Worthington Pump 785281 1/02/81 same as bearing retainer original BF-19 Vulcan Globe 788048 2/03/81 same as Valve original Valve stem 141570 4/22/86 same as original Within the scope of this inspection for the feedwater system, the replacement parts and materials were equivalent to original parts in quality, and their procurement controls were consistent with those of safety~related parts and components. 'No unacceptable conditions wer identifie No violations were identifie.
System.Design and Modifications The condensate and feedwater systems at each of the Salem units consist of three condensate pumps, three parallel low pressure heater strings, a full-flow condensate polishing unit, two steam-driven steam generator feedwater pumps (SGFP), three parallel high pressure feedwater heaters, followed by air operated feedwater control valves (BF19) and low flow bypass valves (BF40).
Heater drain pumps provide additional water inventory at the SGFP suctio The condensate polishers were not in the original system desig The Unit 2 polishers were operational at plant licensing and the Unit 1 polishers were installed during the first refueling outag As stated in the Updated Facility Safety Analysis Report (UFSAR), Section 10.4.7.1.1, the design codes for feedwater piping were ANSI 831.7 (1969) inside containment and ANSI 831.1.0 (1967) outside containmen The inspectors reviewed a.number of proposed and completed design changes made to the feedwater syste Since the licensee uses the same design change control and documentation system for all facility modifications, ~n extensive and complete record exists for all modifications, regardless of system and component classification. A number of system and component modifications were made in response to plant events which were initiated
by the feedwater syste Typically, these resulted from post-trip reviews. However, several analyses were conducted which were broader in scope and which served to focus on system vulnerabilitie The first of these analyses reviewed was completed in 1982 following a series of feedwater pump trips resulting from low suction pressur The analysis was done on a synergistic system basis covering the steam, condensate, and feedwater syste In this broader view, secondary system interactions leading to low feedwater pump suction pressure were analyzed to better determine root caus In general, part of the problem was the addition o_f the full flow polisher to the original system design. The additional pressure drop tbrough the polisher put SGFP suction pressure closer to the trip point, making the system less forgiving of secondary plant transient This was compounded by reduction in heater drain flow on power reduction, a condition which then had to be compensated by increased condensate flo A proposed corrective action was an upgrade of the condensate pumps' head-capacity. This action has been completed on both units within the last yea A.second detailed analysis, completed in December 1986, dealt with operation of the steam dumps or turbine bypass valve syste The licensee recognized that the original steam dump system, twelve valves operating in ganged groups of three, was oversized, tended to overlift, and had a control system which did not lend itself to low power pressure contro The system had been designed primarily to handle high power transients and did not perform well at low power levels. A design modification, changing valve trim, controls, and ~equencing the operation of the firsi six valves has been completed on Unit 2 and is scheduled for installation on Unit The inspector reviewed a licensee prepared printout showing the status of all proposed design change requests related to the condensate and feedwater system All facility modifications, regardless of safety classification, are tracked and documented in the same system in accordance with licensee procedure GM8-EMP-009, Operational Design Change Control, Revision 1, dated August 1, 198 Since a single system is employed, detailed design change inform_ation is readily available for historical revie Since licensing of the plants, 173 design changes have been proposed for these systems in Unit 1, 98 changes have been proposed for Unit Recently, management initiated an effort to reevaluate all outstanding changes to focus attention on those w-ith significance to system reliabilit As a result, 91 chan~es on Unit 1 and 61 changes on Unit 2 were cancelle The remaining design modifications are complete or in progres The inspector also reviewed the following specific modifications which were intended to correct conditions responsible for plant trips: DCP No EC1207 and 2EC125 These design changes on Unit 1 and 2, respectively, were completed in early 1983 (1) and early 1984 (2).
The modification provides narrow range control room indication of feedwater flow and steam flow as a means of providing better information to the operator during low power operation, especially with feedwater flow control in manua An
additional feature provided is automatic control capability for the feedwater flow control bypass valves (BF40 1s).
This allows an earlier shift to automatic level control, reducing the time necessary for the operator to maintain level control in manual on four steam generat~rs simultaneousl Also re~iewed were DCP Nos. 1EC1380A and 2EC1381 These modifications - -
were completed in late 1986 on both unit As discussed above, the design changes upgraded the condensate pumps to provide better head-flow characteristics. The modification consisted of replacing the condensate pump impeller with a nine stage impeller and replacing the 3000 BHP motors with 4000 BHP motor Discussions with plant personnel and review of status records indicated that a number of other modifications have been completed to improve system operatio These include: providing a two level feedwater suction
- pressure trip (190 psi, and 215 _psi with 5 second time delay), the addition of diodes in feedwater pump controls to reduce noise induced signals, deletion of interlocks with valves in the low pressure
recirculation system which have caused pump trips, and modifications to the SGFP annunci~tor panel to provide more useful first-out indicati6n to assess reasons for pump trip In the above cases, continuing attempts to improve system operation and assessment capabilities were eviden In each case~ appropriate codes were called out in the design dotumentation, retests were specif~ed and documented, and operators were trained in the modifications by way of the operations newsletter and inclusion in the requalification program.* In almost all cases reviewed, procedures had been changed to reflect the modified syste *
An examination of plant trips (particularly those involving the main feedwater system) indicates that recent trips are not related to the recurring and chronic pr_oblems seen in the early 1980 1 Since recent tr1ps appear to be the result of new problems, the licensee is also exploring the possibility of making the entire system more forgiving in the event of transients such as loss of a main feedwater pum Proposals being reviewed by the licensee include the installation of an automatic runback in the Electro-Hydraulic Control (EHC) system to reduce power at a predetermined rate in the event of an SGFP los The EHC is currently set up to manually initiate this runback by depressing one pushbutto The licensee is also evaluating reactor protection system setpoint changes in order to increase sy~tem flexibility, These will be subject to NRC review as part of a Technical Specification change request, The in~pector found that the licensee is making changes to the system as analysis dictates the nee The changes are consistent with the construction codes u~ed, and the changes appear to have been effective in reducing trips which have a feedwater system implicatio No violations were identifie *-,(
17 Management Support Management has committed to improvements in Balance of Plant (BOP) and issued an Administrative Procedure AP-41 which delineites the systems which will be encompassed by the program to enhance reliability of station operatio The program-is designed to reduce challenges to safeguard systems r_eleases to the environment and significant capital ris This
- procedure outlines the responsibilities ~f the plant managers with regard to maintenance, purchasing of materials, and quality assurance surveillance of the system The following is a list of BOP systems included in AP-41:
Main steam system piping and valves between MSIVs and main turbine condensate, feedwater, and heater drain pumps, piping, motor-operated valves, check valves, control valves, and flow control syste (Vent and drain valves and valves less than 2 11 are exempt from the program unless specifically identified.)
Main turbine, generator, electro-hydraulic control system, lube oil system, generator cooling system, and hydrogen seal oil system Main turbine gland seal steam pressure controller Main condenser, circulating water pumps, and screens Feedwater heaters, moisture separator reheaters, extraction steam piping, heater drain valves, and heater level control systems Turbine auxiliary cooling system Station air compressors, air dryers, and filters Main station power, and auxiliary power transformers 4160 VAC and 480 VAC group buses, breakers, and relays affecting the above-listed equipment Reactor control systems and M/G power supplies (not reactor protection system)
Non-safety-related instrument bus and power supply inverters Management has created groups that function to identify and track items which could challenge the safeguards system These groups, described below, create reports for upper management to b~come aware of BOP problem Several of these groups were instrumental in major modifications to the facility which have aided in reducing feedwater related trips, such as the steam dump refinement described in section Reliability Group - Reviews IE notices, NRC inspection reports, SALP reports, INPO reports, vendor technical bulletins, etc. to generate a computerized document which delineates if_further action is required on the part of management to address any potential generic concern ;.
Salem Trip Reduction Task Group - Serves to study the above mentioned reports to apply the information to reduce challenges to the safeguards system On Site Safety Review Group - Reviews each reactor trip or safety system challenge in depth to identify trends and corrective measures to prevent recurrenc This is in addition.to the required Site Operations Review Committee meetings for post-trip revie Morning Meetings - Serve to identify any daily problems in BOP and corrective measures in progres The resident inspectors attend these meetings on a daily basi The licensee has members in the following industry organization Nuclear Utility Management Advisory Committee Electric Power Research Institute Institute of Nuclear Power Operations Westinghouse Owners Group These members serve to bring generic issues to the attention of management for resolution as they may apply to Sale The licensee also sends managers and engineers to other facilities (including severaJ in Europe)
to investigate and study new ideas to incorporate into BOP system Management has provided adequate resources to the betterment of BOP system Management policies and attitudes regarding BOP are understood and implemented down to the worker level Management is involved and strongly interested in reducing challenges to the safety systems from the BOP and have expended both time and resources to reach their goal of 3 or less reactor trips per unit per yea (The industry average is 4.3 trips per unit per year).
No violations were identifie.
Summary of Findings Strengths There is strong management support for trip reduction that is evident from the Senior Vice President to the worker level.
. 10 CFR 50.59 reviews and design changes to BOP are well documented and are reflected down to control room procedure There is active participation in industry groups as a whole and in particular in the trip reduction effor There are strong review groups on site that analyze*and document trips and root cause _
_, especially for generic trend,,
There is the beginning of strong failure analysis and performance monitoring program *.
Recent operator errors are not similar to those of the pas A reduction in trip frequency has been noted and the trips have very little similarity to each other - they ~ppear to be random in.natur Weaknesses Operating procedures, although understood by operating personnel, did not always reflect changes made to plant system There was evidence of missing gages and valve stem protectors; some insulation was not replaced and small leaks were noted o~ the system wa l kdown In addition, there was a perception on the part of the team that the plant betterment engineering department and nondestructive testing groups off site needed to communicate more with the on site groups to more fully understand the newly instituted preventative and predictive maintenance program No violations were identifie.
Exit Interview At periodic intervals during the course of the inspection, meetings were held with senior facility -management to discuss the inspection scope and finding An exit interview was held with licensee management at the end of the reporting perio The licensee did not identify 2.790 materia,
- .1 NAME B. M. Connor P. J. Landers D. J. McCollum L. K. Miller S. E. Miltenberger J. W. Morrison D. A. Perkins G. A. Roggio D. K. Strong C. M. Williamson J. M. Zupko, J W. M. Hill T. J. Kenny L. J. Norrholm A. J. Szczepaniec NAME B. M. Connor M. K. Gray D. J. McCollum
.L.K.Miller D. A. Perkins B. A. Preston G. A. Roggio J. P. Ronafalvy C. M. Williamson J. M. Zupko, J J. W. Chung W. M. Hill T. J. Kenny L. J. Norrholm APPENDIX A ENTRANCE PSE&G NRC TITLE Salem Operations Staff Principal Training Supervisor System Engineer
Assistant General Manager - Salem Operations Vice President - Nuclear Operations Maintenance Engineer - Salem Manager - Station Quality Assurance Station Licensing Engineer Maintenance Engineer - Electrical Controls Senior Staff Engineer General Manager - Salem Operations Senior Reactor Engineer Senior Resident Inspector - Salem Section Chief SIB-HQ Reactor Inspector (Region II)
EXIT PSE&G NRC TITL Salem Operations Staff Licensing Engineer System Engineer Assistant General Manager - Salem Operations Manager - Station Quality Assurance Manager - Licensing and Regulation Station Licensing Engineer Technical Manager - Salem Senior Staff Engineer General Manager - Salem Operations Lead Reactor Engineer Senior Reactor Engineer Senior Resident Inspector - Salem Section Chief SIB-HQ
'
!
YEAR 1976 Dec. Only 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 TOTAL OPERATOR CAUSED
1
5
2
41 OPERATOR CAUSED APPENDIX B FEEDWATER INDUCED TRIPS MAIN FEED REG. VALVE MAIN FEED PUMP INSTRUMENT OTHER
-
1 TOTAL
~
18
2
39
j
.. UNIT 1 ONLY UNIT 2 START lST TRIP 5/20
.... 0 D-16 POST TRIP VIEWS START PRIL
RE A
4 9.
118
-
Trips caused during the operation of the unit through faults of the operator or procedural error MAIN FEED REG. VALVE -
Trips caused by the malfunctioning of the feed regulation valves (BF-19's) or feed bypas.
MAIN FEED PUMP INSTRUMENT OTHER
-
Trips caused by the malfunctioning of the main feed pump, including control instrumentation for the feed pump onl Trips caused by control instrumentation related to the feed system eg. feed flo~1/steam flow or S/G leve Any other category that could not be fit into the first four categorie *
Number Revision IOP-3
IOP-4
IOP-5
OP-III-9. OP-III-9. OP-III-9. OP-III-9. OP-III-12.3.2 1 OP-III-12.3.3 1 EI I-4.12
APPENDIX C DOCUMENTS REVIEWED Title Hot Standby to Minimum Load Power Operation Minimum Load to Hot Standby Placing Feed and Condensate System in Service Feed Pump Operation Condensate Pump Strainer Cleaning Feed Pump Strainer Cl~aning Returning a Feedwater Heater Group to Service Removing a Feedwater Heater Group from Service Loss of Feedwater Tri12 N Work Order Date Work Order N Egui12ment 84-02 11/22/84 942135 1CN47 84-09 6/15/84 948661 14BF40 10/04/84 948665 23BF19 84-14 8/27/84 9909921 21SFGP 8/27/84 99102943 21SGFP 9/20/84 84082goo15 21SGFP fl ow 8/27/84 8408270346 21SGFP turbine 9/24/84 99098989 21SGFP turbine 84-15
- 9/05/84 0099100011 22SGFP 84-21 1/17/85 0099104261 11BF19 86-02 2/02/86 0099180081 11BF40 86-03 2/20/86 0099182858 14BF19 86-04 5/29/86 009918440 BF19 86-08 6/13/86 8606120499 13CN27 86-12 7/21/86 0099170116 21SGFP governor 86.,.13 8/11/86 8608050391 llSGFP overspeed 8/08/86 8608050382 llSGFP 8-6-18
- 12/28/86 0099171198 23SGFP
- 12/29/86 8612290015 23BF19
- those reviewed from computer files
r-~-
I *. Reactor Cool ant APPENDIX D VODAP RANKING Reactor Protection and Control Service Water, Turbine/Nuclear Area VAC eves NIS SIG Feed and Condensate Auxiliary Feedwater Rod Contra 1 1 Diesel Generator 1 DC Distribution 1 Vital HVAC 1 Containment Building Ventilation 1 RHR 1 Component Cooling 1 EHC 1 Radiation Monitoring 1 Circulating Water, Screen Wash 1 SIS 2 SIG Feed Pump Lube Oil 2 RP I 2 KV Switchgear and Bus 2 Main Steam and Turbine Bypass 2 Compressed Air 2 Main Generator 2 Bleed Steam, Heater Drain 2 VAC Switchgear 2 Heat Tracing 2 Gas Turbine 3 Waste Liquid, Radioactive 3 Gland Seal Steam and Leak Off, Turbine 3 Waste Gas, Radioactive 3 SIG Drajns and Blowdown 3 Condenser Air Removal 3 MSR, Drains 3 Condensate Polishing