IR 05000285/1985006

Insp Rept 50-285/85-06 on 850301-0430.No Violations or Deviations Noted.Major Areas Inspected:Previous Insp Items, Operational Safety Verification,Surveillance Testing & Maint & Outage Activities

ML20126L709
Person / Time
Site:	Fort Calhoun
Issue date:	06/12/1985
From:	Martin L, Yandell L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20126L698	List: IR 05000285/1985006 ML20126L695
References
50-285-85-06, 50-285-85-6, NUDOCS 8506200120
Download: ML20126L709 (10)

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I APPENDIX U. S. NUCLEAR REGULATORY COMMISSION

REGION IV

NRC Inspection Report: 50-285/85-06 License: DPR-40 Docket: 50-285 Licensee: Omaha Public Power District 1623 Harney Street Omaha, Nebraska 68102 Facility Name: Fort Calhoun Station Inspection At: Fort Calhoun Station, Blair, Nebraska Inspection Conducted: March 1-April 30, 1985 Inspector- f

. K. 4 andell,~Ss or Resident Reactor Inspector MMAS Dat(

Approved: / //MJS, L." B( Martin, Se ion Chief, Prcject Section A, Date'

t Reactor Proje t Branch 2 Inspection Summary:

Inspection Conducted March 1-April 30, 1985 (Report 50-285/85-06)

Areas Inspected: ' Routine, unannounced inspection of licensee action on previous inspection findings, operational safety verification, surveillance

._ testing, maintenance activities, and outage activities. The inspection involved 122 inspector-hours onsite by one NRC inspector, of which 42 were offshift hour Results: Within the five areas inspected, no violations or deviations were identifie >

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h 2 Persons Contacted

• R. L. Andrews, Division Manager, Nuclear Production

• K. J. Morris, Manager, Quality Assurance

• R. L. Jaworski, Section Manager, Technical Services

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• J. K. Gasper, Ma'iager, Administrative Services

• G. Gates, Manager, Fort Calhoun Station

! *P. M. Surber, Section Manager, Generation Station Engineering i

• J. J. Fisicaro, Supervisor, Nuclear Regulatory and Industry Affairs

• M. E. Kallman, Supervisor, Administrative Services & Security M. R. Core, Supervisor, Maintenance A. L. Richard, Supervisor, Technical L. T. Kusek, Supervisor, Operations R. J. Mueller, Supervisor, I&C and Electrical Field Maintenance J. J. Fluehr, Supervisor, Station Training

• Denotes attendance at the exit intervie The NRC inspector also talked 'with and interviewed other licensee employees during the inspection. These employees included licensed and unlicensed operators, craftsmen, engineers, and office personne . ' Licensee Action on Previous Inspection Findings

, (Closed) Violation 285/8412-01, " Independent Verification." The licensee failed to require independent verification a '.ag-outs to ensure that equipment was properly isolated. Standing Order 0-20,

" Equipment Tagging Procedure," was revised to require the craftsman to verify that the equipment is properly isolated. This is done by

" personally verifying that tags have been hung in accordance Mth the tag-out sheet and that tagged components are in their requirm'

position" or by " personally checking the adequacy of the comp. rat tag-out to ensure that it is safe for maintenance to proceed." The procedure provides new tag-sheets with a carbon copy that is to be attached to the maintenance order (MO) or applicable document to aid the craftsman in verification of a proper tag-out. The craftsman is required to sign the carbon copy to document the verification. The NRC inspector has observed this new system in operation and on several occasions reviewed MO packages to verify that the carbon copy was attached and signed off as required. This item is considered close (Closed) Violation 285/8429-02, " Improper Valve Lineup." While performing Valve Checklist OI-CS-1-CL-A, " Containment Spray System,"

the NRC inspector found SI-342 closed and unlocked when the checklist required that the valve be closed and locked. The valve was immediately locked by operations personnel and verified by the NRC inspector. The valve had been operated during a short maintenance L

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outage as Step IV.Q of Operating Instruction 01-RC-4, " Reactor Coolant System Normal Shutdown," to aid in the pressurizer cooldow Step IV.U called for the valve to be closed, but did not state that-the valve was to be locked. 01-RC-4 was revised to require that SI-342 be closed and locked in Step IV.U and the NRC inspector has verified the status of this valve on a monthly basis since this violation. This item is considered close . Operational Safety Verification The NRC inspector performed activities as described below to ascertain that the facility is being maintained in conformance with regulatory requirements and that the licensee's managcment control system is effectively discharging its responsibilities during power operatio The NRC inspector made several control room observations to verify proper shift manning, operator adherence to approved procedures, adherence to selected Technical Specifications, and operability of the reactor protective system and engineered safeguards equipmen Selected logs, records, recorder treces, annunciators, panel indications, and switch positions were reviewed to verify compliance with regulatory requirements. The licensee's equipment control was reviewed for proper implementation by reviewing maintenance order status and the tag-out log, and by verifying selected safety-related tag out The NRC inspector observeu several shift turnover The NRC inspector toured the plant at various times to assess plant and equipment conditions. The following items were observed during these tours:

. general plant conditions

. vital area barriers not degraded or appropriately manned by security personnel

. adherence to requirements of radiation work permits (RWPs)

, proper use of protective clothing and respirators

. plant housekeeping and cleanliness practices including fire hazards and the control of combustible material

. work activities being performed in accordance with approved activities

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. physical security

. HP instrumentation is operable and ca'ibrated I _ _ _

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c. The NRC inspector verified operability of the following safety-related systems by performing a walkdown and switch verification of the accessible portions of the system:

. Auxiliary Feedwater per Checklist ST-FW-1-CL-A

. Gaseous Waste Disposal System per Checklist WDG-1-CL-8

. Plant Electrical Distribution, 480V system per Checklist EE-2-CL-D

. Engineered Safeguards Controls per Checklist ES-1-CL-A d. The NRC inspector observed portions of Containment Purges 85010, 85012, 85015, and 85018, reviewed the discharge permits, and noted the following for each:

. the X/Q log was maintained, the readings were within limits, and the shift supervisor review was performed

. the limiting X/Q was established

. VIAS was tested using either RM 060 or RM 061

. the stack dewpoint and annubar readings were taken

. the tritium sampler was in place and the sample was taken

. the recommended release rate was established, and the actual flow was lower than that authorized

. radioactivity analyses were performed

. the required effluent monitors and recorders were operational

. the required auxiliary building exhaust fans were operating

. OI-VA-1,Section IV.G was attached to the permit t

. ti)e initial reading of the stack flow integrator was noted on the recorders

. the operations checklist to CMP 4.5 was complete and signed off by the shift supervisor  ;

. the permit was reviewed and signed off properly, and the termination time was established

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Purge 85015 was performed under the new requirements of Section VIII of CMP 4.5 that established more definitive limits for terminating the release. In conjunction with these limits, " alert" setpoints on Discharge Monitors RM 050 and RM 051 were reset to give operators an indication of any increase in discharge activit The NRC inspector observed the work performed by the I&C technicians, and verified that it was documente The NRC inspector reviewed the completed Discharge Permits 85004 and 85005 to verify that HP personnel performed final calculations and verifications to establish actual quantities released and to confirm that Technical Specification release limits were not exceede e. The NRC inspector observed portions of the following waste tank discharges:

. Discharge Permit 85011 "B" Waste Gas Decay Tan The NRC inspector verified that the X/Q and stack dewpoint logs were maintained, the operations checklist was completed and signed off, the maximum release rate was established, the required recorders were operational, and the start time was recorde . Discharge Permits 85033, 85039, and 85059 "A" Monitor Tan The NRC inspector verified for each permit that tank sample had been taken, that all radiological and chemical discharge limits were satisfied in the discharge tunnel, that the operations checklist was signed off, that the maximum release rate was established, and that the shift supervisor had signed off the permi For Permit 85033, the NRC inspector observed the valve lineup, testing of the overboard valves, and initiation of the discharge with the auxiliary building operator at AI-10 f. On March 7, 1985, the NRC inspector administered an SRO requalification retake examination to two Fort Calhoun personnel who had failed to pass the initial requalification examination given in November 198 The examination was provided by the Region IV Operator Licensing Section and personnel from that organization were consulted by phone to resolve questions raised by the examinees. An exam review was conducted with the licensee and these comments were summarized in a conference call with the Region IV staff as well as forwarded by letter for NRC consideration. The licensee was informed later that month that both candidates had passed the requalification examination.,

g. The NRC inspector reviewed the plant manuals maintained at the remote shutdown panel in Room 57 and verified that the current revisions of Emergency Procedures EP-1 through EP-38 were presen h. On March 20,'1985, the NRC inspector observed an emergency preparedness drill being conducted by the license It was noted b

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l that the drill crew diagnosed the simulated plant casualty, established the proper emergency classification, and implemented the

appropriate response activities. The NRC inspector reviewed the l 1,nif t Supervisor's Emergency Checklist booklet and verified that

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current revisions of appropriate Emergency Plan Implementing Procedures were present.

No' violations or deviations were identifie . Surveillance Testing The NRC inspector witnessed portions of the following surveillance tests

. ST-ICI-2,' F.1 (Monthly) Incore Detector Alarm Limits Verification l

l ST-FP-10, F.2 (18 Months) Visual Inspection of Halon System ST-ISI-CVCS-3, F.1 (Quarterly) Chemical and Volume Control Pump Inservice Testing ST-RPS-1, F.3 (Monthly) Power Range Safety Channels Test

^ ST-RPS-4, F.2 (Monthly) Thermal Margin / Low Pressure Channels Test ST-ESF-6, F.2 (Monthly) Diesel Generator Check l ST-RM-2, F.2 (Monthly) Process Monitor Checks

' ST-FW-3, F.2 (Monthly) Auto Initiation of Auxiliary Feedwater;

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Functional Check of Initiation Circuits

, ST-PL-1, F.2 (Monthly) Pressurizer Level Channel Control Check l ST-PORV-2, F.1 (Quarterly) PORV Block Valve Operation ST-DC-1, F.1 (Monthly) Station Battery Checks ST-FW-1, F.2 (Quarterly) Auxiliary Feedwater Pump and Remotely Operated Valve Check In the above surveillance tests, the NRC inspector verified where applicable that:

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. testing was scheduled in accordance with Technical Specification requirements

. procedures were being followed

. calibrated test equipment was being used

. qualified personnel were performing the tests k

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. limiting conditions for operation were being met

. . test data were being accurately recorded No violations or deviations were: identifie '5J Maintenance Activities The NRC inspector witnessed portions of the work performed on the-following maintenance items:

, MO 843745, "B Concentrate Tank Outlet Pipe Replacement." A leak was '

~ identified on the pump suction piping, and the NRC inspector verified

that a PRC approved procedure was prepared to cover this work. QC

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requirements were established for a certified welder, the weld rod, and the welding procedure. The NRC. inspector noted that QC performed a visual inspection after the weld repairs were completed, and all material used was identified on the MO. Tag-Out 84-1625'was-assigned to this work. .The NRC inspector reviewed the work procedure and .,

verified that the prerequisites were signed off, QC hold points were observed, the calibration gauge was identified and calibrated before

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-and after the leak test, the safety analysis was completed and attached, and Procedure Changes 13768,_13798, 14065, and 14196 were attached and properly entere MO 850935, " Breaker for Raw Water Pump AC-10A." The NRC inspector observed performance of preventive maintenance under Procedure PM-EE-1.1, " Type Am-4.16-250 Magne-Blast Circuit Breaker,"

and noted that the correct procedure revision was being used, that the precautions and limitations were signed off, that the QC signoff was present, and that qualified craftsmen were assigned to the jo Tag-Out 85-289 was assigned to this work, and the NRC inspector v'erified the placement of these tags.

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During the performance of Item 6.3.6.1.c, it was determined that the main contact wipe was out of the specified rang This M0 was w'ritten to cover the maintenance done to correct this proble The I' NRC inspector observed the preparation, review, and approval of the M0.and verified that it was properly filled ou The NRC inspector

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observed the work performed to correct the problem and the remaining portion of the preventive maintenance procedur M0s 850655 and 850656, " Perform Qualified Life PM as per PM-EE-12."

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These M0s covered work performed on Containment Fans VA-3A and VA-3B -

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qualified life on the motors, Procedure PM-EE-12, " Vent Air Fan Motors VA-3A, 3B, 7C, 2A, 2B, 12A and 128," was performed. The NRC inspector reviewed the completed M0s and procedures, verified that bearing lubrication was done with required lubricant, and that vibration readings were take The NRC inspector reviewed Tag-Out.

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.85-220 assigned-to this job and verified that signoffs were complete, the applicable. Technical Specification was identified, and qualified personnel were assigned to perform the wor M0 850770, "Feedwater Control to Steam Generator A." The operators

, observed that the "A" Steam Generator level was varying more than normal. The NRC inspector observed the preparation of the M0 and observed troubleshooting being performed by I&C personnel. It was noted that the MO was filled out and properly approved, and that the applicable referenced drawings were available at the worksit ~ M0s 851540 and 851541, " Perform MP-LS-1 to Maintain Qualified Life."

Maintenance was done on the NAMCO limit switches on Cooling Water Valves HCV-2899A and HCV-2898A (Control Room A/C Units 468 and 46A respectively) to maintain their qualified lif Procedure MP-LS-1, " Limit Switch Type EA 180 Preventative Maintenance to Maintain 79-01B Qualification," calls for inspection and lubrication of the limit switch, replacement of the bottom cover gasket, the lever shaft and the~o-ring assembly, cleaning of the contacts, and measurement of the contact resistanc The NRC inspector verified that the M0 was signed off properly, that QC signoffs were present, and that all spare parts utilized were identified on the M0. Procedure MP-LS-1 was filled out correctly, QC hold points were observed, qualified personnel were assigned to the job, and Form 198, " Electrical Equipment Qualification / Qualified Life Program," information sheet was filled ou MO 851034, " Low Pressure Safety Injection Pump SI-2C." This maintenance item covered the performance of MP-EE-8, " General Electric 8000 Series Horizontal Induction Motors," to maintain the qualified life of the moto This work included cleaning the motor and air openings, inspecting the motor bearings and bearing housing,

-draining and flushing the motor lubrication system, meggering the motor, and testing the uni The NRC inspector verified Tag-Out 85-325 for this work and noted

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that the applicable Technical Specification was referenced on the M Following completion of the work, Surveillance Test ST-SI/CS-1,

"SI/CS Pumps and Valves," was performed on SI-2C to verify operability and Form FC-198 was filled out and submitted with the M 'g .' MO 851134, " Changing Isolation Valve to Loop 1A, HCV-247."

, Valve HCV-247 was shut while performing Surveillance Test ST-ISI-CVCS-1, F.1, "CVCS Category B Valve Exercising Test," and would not reopen. The NRC inspector observed troubleshooting performed by I&C technicians who checked for grounds and verified

. solenoid operabilit After consultation and evaluation, the licensee secured the charging pump and the valve opened. Normal charging was. reestablished and the surveillance performed again to

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verify that the valve would go shut. It appears that the problem is mechanical at the valve itself, which is inaccessible during

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operation. The licensee annotated the completed surveillance test with the condition of the valve, tagged the control board switch with the appropriate status information regarding closing of the valve, and kept this M0 open pending shutdown to allow examination and repair of the valv No violations or deviations were identifie . Outage Activities While performing a surveillance test on February 19, 1985, the licensee determined that Control Element Assembly (CEA) 22 failed to move. As discussed in NRC Inspection Report 50-285/85-05, paragraph 5.e, -the licensee was considering shutting down "to change the drive package and correct the problem."

On March 15, 1985, the licensee initiated a weekend shutdown to change out the drive package on CEA 22. Procedure OP-8, " Reactor Shutdown," was modified by Procedure Change MO 13540 to account for CEA 22, and it was reported to the NRC inspector early the next day that the CEA dropped in

,1.6 seconds as expected. This confirmed that the problem was with the

, ' electrical drive package and not " excessive function or mechanical interference" with the CEA itsel MO 850419, " Replacement of CEA 22 Drive Package," was issued to cover this repair, and the NRC inspector verified that a PRC approved procedure was attached to the M0, that the MO was properly signed off and approved, that. Tag-Out 85-211 was properly

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hung, and that qualified personnel were assigned to the job. During the shutdown the NRC inspector reviewed the Technical Specifications associated with containment integrity and shutdown margin, and verified

, that the licensee was in compliance. During a tour of the auxiliary building the NRC inspector observed that guards were properly posted at the containment entrance, that accountability was being maintained, and that required radiological controls (including full face mask) were in

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effect. Other activities planned during this short outage included work on the stator cooling system, examination of the position indications on HCV-2500 and HCV-2501, repair of HCV-311 Limit Switch, and performance of various preventive maintenance (EEQ related) procedures on containment equipmen The plant started up on Sunday, March 17, 1985, and was at 30 percent power the next morning waiting for secondary chemistry to come into specificatio The NRC inspector observed portions of Startup 85-01 and reviewed the following startup documents:

. CO-5-CL-A, " Containment Integrity," Checklist

. ST-ESF-6, F.1, " Diesel Auto Start Initiating Circuit Check," for both diesel generators L:

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. ST-RPS-2, F.2, " Wide Range Logrithmic Channel Functional Check"

. ST-RPS-9, F.1, " Turbine Loss of Load Channel Check"

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. ST-RPS-10, F.1, " Manual Trip Check"

. ST-CEA-1, F.1, "CEA Drive System Interlocks Check"

. CO-1-CL-A, " Containment Closure Checks"

. Shutdown Margin Worksheets

. OP-8, " Reactor Shutdown"

. OP-5, " Plant Shutdown"

. OP-7, " Reactor Startup"

. Estimated Critical Boron Concentration Work Shee The estimated critical boron concentration was 698 ppm and the actual critical baron concentration was 715 pp . OP-3, " Plant Startup from Hot Standby to Minimum Load."

No violations or deviations were identifie . Exit Interview The NRC inspector met with licensee representatives on May 3, 1985, to summarize the scope and findings of the inspectio s