IR 05000285/1986023

Partially Withheld Insp Rept 50-285/86-23 on 860801-0930 (Ref 10CFR73.21).Violations Noted:Inadequate Control of Safeguards Info & Failure to Identify Diagram as Safeguards Info

ML20213E967
Person / Time
Site:	Fort Calhoun
Issue date:	10/31/1986
From:	Harrell P, Hunter D, Murphy M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20213E949	List: IR 05000285/1986023 ML20213E947
References
50-285-86-23, NUDOCS 8611130393
Download: ML20213E967 (12)

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AFPENDIX B

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U. S. NUCLEAR REGULATORY COMMISSION

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REGION IV

NRC Inspection Report: 50-285/86-23 License: DPR-40 Docket: 50-285

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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: August 1-September 30, 1986 Inspector: I

- t R. H.'ttfrW Senior Resident Reactor

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%ispector(pars. 2,3,5,6,7,8,9,10,11)

A4-12h W ~

l G l51 b M. E. ~ Murphy, ProJec't Inspector, Project Date Section B, Reactor Projects Branch (pars. 4,5)

Approved: )

D. R. Hunter, Chief, Project Section B,

' 10 !7 f 6 Date Reactor Projects Branch REMOVAL OF THE PAGES MARKED " "

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Inspection Summary Inspection Conducted August 1 through September 30, 1986 (Report 50-285/86-23)

Areas Inspected: Routine, unannounced inspection including operational safety verification, maintenance, surveillance, plant tours, safety-related system walkdowns, security observations, review of the tests and experiments program, followup on previously identified items, followup on a licensee event report, and management organizational change Results: Within the 10 areas inspected, 2 violations (inadequate control of safeguards information and failure to identify a diagram as safeguards information, Appendix A) were identifie REMOVAL OF THE PAGES MARKED " "

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DETAILS

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i Persons Contacted

• R. Andrews, Division Manager, Nuclear Production Division i *W. Gates, Manager, Fort Calhoun Station

. C.- Brunnert, Supervisor, Operations Quality Assurance

M. Core, Supervisor, Maintenance r *J. Fisicaro, Supervisor, Nuclear Regulatory and Industry Affairs

, J. Foley, Supervisor, I&C and Electrical Field Maintenance

• J. Gasper, Manager, Administrative Services

• R. ~Jaworski, Section Manager, Technical Services M. Kallman, Supervisor, Security j L. Kusek, Supervisor, Operations

D. Munderloh, Licensing Engineer i T. McIvor, Supervisor, Technical

! R. Mueller, Plant Engineer I *A. Richards, Manager, Quality Assurance

G. Roach, Supervisor, Chemical and Radiation Protection l J. Tesarek, Reactor Engineer

] P. Walling, Supervisor, Administration Services

! S. Willrett, Supervisor, Administration Services and Security

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• Denotes attendance at the monthly exit interview, i The inspector also contacted other plant personnel, including operators, technicians, and administrative personnel, f Followup on Previously Identified Items

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{ (Closed) Severity Level V violation 285/8503-04: Failure to have i procedures for identification of safety-related piping requiring inservice l

inspection (ISI).

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! The licensee reviewed documentation and confinned that the safety

injection recirculation piping was not included in the ISI program. The

recirculation piping is buried in concrete and not accessible for

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! The licensee requested that the NRC's Office of Nuclear Reactor t Regulation (NRR) approve the use of ASME Code Case N-408 for exemption

from ISI requirements for this particular piping installatio In a letter dated June 24, 1986, NRR provided approval for the lia to

. apply Code Case N-408 to the ISI requirements for the buried piping. Code i Case N-408 allows the recirculation piping to be exempt from ISI requirements. Based on this approval by NRR, the licensee is not required to perforin ISI activities on the buried recirculation piping.

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~(Closed) Open Item 285/8602-01: Update of Procedure MP-EE-8 to clarify

, maintenance instructions for equipment qualification (EQ) consideration ! The licensee has issued a revision to Procedure MP-EE-8, "GE 8000 Series i Horizontal Induction Motors," for clarification of maintenance

. instructions for the safety injection pump motors (i.e., high-pressure,

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low-pressure, and containment spray). Revision 3, dated May 11, 1986, to i Procedure MP-EE-3 added the instructions for draining of oil and for inspection of the motor leads and splices for cracks, discoloration, and other signs of physical damag *

i The NRC inspector reviewed Revision 3 to Procedure MP-EE-8. Based on the

review, it appears that the licensee has adequately revised the procedure-

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for oil draining and motor lead inspection instruction i (Closed)OpenItem 285/8602-02: Procedure revision for addition of EQ

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activities.

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Thelicenseehasissuedpreventivemaintenance(PM)instructionsto require that the motor bearings in the containment vent fan motors be changed. The PM instructions require that the motor bearings be changed every 100,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> of operation.

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The NRC inspector reviewed the PM instructions. No problems were noted.

f (Closed)OpenItem 285/8602-03: Revision of Procedure MP-VA-81 to correct i maintenance instructions for EQ considerations.

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The licensee has issued a revision to Procedure MP-VA-81, " Hydrogen Monitors," for correction of maintenance instructions for the hydrogen j monitors. Revision 1, dated June 19, 1986, to Procedure MP-VA-81

corrected the instructions for which type of grease and the amount of j

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grease to be used for lubrication of the monitor ,

l The NRC inspector reviewed Revision 1 to Procedure MP-VA-81. Based on

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this review, it appears that the licensee has adequately corrected the j procedure for the grease type and amount to be used, i

! (Closed)OpenItem 285/8602-05: Revision of drawings to show installation j of cable splice During EQ activities, the licensee noted that the qualification for specific terminal blocks could not be established. The licensee replaced

the tenninal blocks with qualified Raychem splices. The licensee has l

urdated the affected drawings to remove the terminal blocks and indicate i replacement with cable splice The NRC inspector reviewed the drawing changes made by the licensee. The NRC inspector verified that the appropriate drawings had been changed for

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the affected instrumentation and that the drawings correctly reflected the

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(Closed) Severity Level IV violation 285/8603-02: Failure to establish an hourly fire patro The licensee has instructed all members of the security force (hourly fire watch patrol) on the importance and necessity of ensuring each degraded fire barrier is checked hourly. The licensee has also made the security officer-in-charge on each shift responsible for verifying that the security force checks all degraded fire barrier The NRC inspector has verified numerous times during the past 3 months that the security force is checking degraded fire barriers. This verification was performed by actual check of security force activities and by reviewing entries on the appropriate radiation work permit (RWP).

The RWP is signed each time a security guard enters the radiation controlled area in the auxiliary building to check degraded fire barrier The NRC inspector has also discussed the importance of checking the fire barriers with individual security guard Each guard interviewed now understands the reason and importance of checking degraded fire barrier . Licensee Event Report (LER) Followup Through direct observation, discussions with licensee personnel, and review of records, LER 86-04 was reviewed to determine that reportability requirements were fulfilled, immediate corrective action was accomplished,

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and corrective action to prevent recurrence had been accomplished in accordance with Technical Specifications (TS).

LER 86-04 reported a manual trip of the reactor from approximately 85 percent power due to smoke being observed in one phase of the isolation phase bus duct. While making his normal hourly rounds of the turbine building, the turbine building operator noted an odor of smoke in the area and an increasing temperature of the bus duct. Upon notification by the operator, a normal shutdown from 100 percent power was initiated. When power reached 85 percent, the bus duct and the ground strap became discolored. The discoloration indicated a worsening condition. To prevent a possible fire in the bus duct, management decided to manually trip the reactor and secure the output of the station electrical generato The NRC inspector reviewed the post-trip evaluation perfonned by the licensee. The review included verification that all equipment functioned normally after the tri No violations or deviations were identifie . Tests and Experiments Program This portion of this inspection was conducted to verify that the licensee has implemented a quality assurance program relating to the control of REMOVAL OF THE PAGES MARKED " "

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tests and experiments that confoms with regulatory requirements, comitments in the application, and industry guides and standard The NRC inspector reviewed licensee Standing Order (S0) G-5, " Fort Calhoun Station Plant Review Comittee (PRC)," Revision 31, dated March 19, 1986; SO G-30, "Setpoint/Procedur Changes," Revision 17, dated September 16, 1985; and SO G-46, " Evaluation of Procedures, Procedure Changes, Tests, and Experiments for Safety Evaluations and Status as an Unreviewed Safety Question," Revision 4, dated November 24, 198 This review verified that a formal method has been established to handle all requests or proposals for conducting plant tests and experiments involving safety-related components, systems, or structures; operation in modes different from those described in the Updated Safety Analysis Report (USAR); all tests and experiments will be performed in accordance with approved written procedures; and responsibilities have been assigned for reviewing, approving, and controlling test and experimental procedures. A fomal system, including assignment of responsibility, has been established to ensure that all proposed tests and experiments will be reviewed to determine whether they are described in the USAR or a written safety evaluation pursuant to 10 CFR Part 50.59 will be developed for each test or experiment not described in the USAR. The review is performed to ensure that the test or experiment does not involve an unreviewed safety question or a change in the T Facility modifications packages FC-86-18 and FC-84-203, as well as facility license changes 85-06 and 86-09, were reviewed. The packages for each was complete and had been developed, processed, and reviewed in accordance with the licensee's formal program and administrative procedure No violations or deviations were identifie . Operational Safety Verification The NRC inspector conducted reviews and observations of selected activities to verify tnat facility operations were performed in confomance with the requirements established under 10 CFR, administrative procedures, and the TS. The NRC inspector made several control room observations to verify:

. Proper shift staffing

. Operator adherence to approved procedures and TS requirements

. Operability of reactor protective system and engineered safeguards equipment

. Logs, records, recorder traces, annunciators, panel indications, and switch positions complied with the appropriate requirements RFMOVAL OF THE PAGES MARKED " "

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i; - . Proper return to service of components i . Maintenance orders (MO) initiated for equipment in need of i maintenance

. Appropriate conduct of control room and other licensed operators No violations or deviations were identifie . Plant Tours The NRC inspector conducted plant tours at various times to assess plant i and equipment conditions. The following items were observed during the tours:

. General plant conditions

. Equipment conditions, including fluid leaks and excessive vibration

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

. Adherence to the requirements of radiation work permits

. Work activities performance in accordance with approved procedures During plant tours, the NRC inspector noted the following:

, . One hundred pounds of oxidizer was stored in the main steam piping area (Room 81) and presented a potential fire hazard. The licensee

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perfonned an evaluation of the oxidizer fire potential and determined that the oxidizer did not cause the transient combustible loading for Room 81 to be exceede . The NRC inspector noted that the emergency diesel generator rooms were dirty and needed additional housekeeping attention. The licensee provided the additional housekeeping attentio . The licensee installed a new fire door in the east entrance to the cable spreading room. Upon replacement, the NRC inspector noted that the door was not reposted to indicate that the cable spreading room was a no smoking area or that immediate evacuation was required if i

the halon system alarm sounded. The licensee immediately reposted the appropriate warning signs.

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No violations or deviations were identified.

j Safety-Related System Walkdowns i

The NRC inspector walked down accessible portions of the following safety-related systems to verify system operability. Operability was

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detemined by verification of selected valve and/or switch positions. For

] the component cooling water system, the NRC inspector verified that

selected snubbers and pipe restraints were properly installed. The systems were walked down using the drawings and procedures noted

! . Plant electrical distribution 4160-volt system

, (Procedure OI-EE-1-CL-A, Revision 9, and Drawing USAR Figure 8.1-1, l Revision 27).

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. Plant electrical distribution 480-volt system

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(Procedure OI-EE-2-CL-A, Revision 9, and Drawing USAR Figure 8.1-1, Revision 27).

. Component cooling water system (Procedure 01-CC-1-CL-A, Revision 19;

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and Drawings 11405-M-10, Revision 37; 11405-N-40, Sheet 1,

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Revision 16; Sheet 2 Revision 14; and Sheet 3, Revision 14).

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During the walkdowns, the NRC inspector noted minor discrepancies of an l editorial nature between the drawings, procedures, and plant as-built

conditions for the selected areas checked in the component cooling water i system. None of the conditions noted affected the operability or safe l

operation of the system. Licensee personnel stated that the noted minor a discrepancies would be corrected. The NRC inspector noted no problems during walkdown of either electrical distribution system.

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i No violations or deviations were identifie . Monthly Maintenance Observation

The NRC inspector reviewed and/or observed selected station maintenance

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activities on safety-related systems and components to verify the j maintenance was conducted in accordance with approved procedures, i regulatory requirements, and the TS. The following items were considered i during the reviews and/or observations: *

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. The TS limiting conditions for operation were met while systems or 1 components were removed from service.

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. Approvals were obtained prior to initiating the wor . Activities were accomplished using approved M0s and were inspected,

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l . Functional testing and/or calibrations were performed prior to j returning components or systems to servic . Quality control records were maintained.

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Activities were accomplished by qualified personne .

Parts and naterials used were properly certified.

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. Radiological and fire prevention controls were implemente The NRC inspector reviewed and/or observed the following maintenance activities:

. Removal and replacement of a raw water pump (M0 862982)

. Repair of toxic gas monitor (TGM) YIT-6286A (M0 863502)

. Replacement of flowmeter on TGM YIT-6288A (M0 852411)

. Repair of the security emergency diesel generator (M0 863426)

No violations or deviations were identifie . Monthly Surveillance Observation The NRC inspector observed selected portions of the performance of and/or reviewed completed documentation for the TS required surveillance testing on safety-related systems and components. The NRC inspector verified the following items during the testing:

. Testing was performed by qualified personnel using approved procedure . Test instrumentation was calibrate . The TS limiting conditions for operation were me . Removal and restoration of the affected system and/or component were accomplishe . Test results conformed with TS and procedure requirement . Test results were reviewed by personnel other than the individual directing the tes . Deficiencies identified during the testing were properly reviewed and resolved by appropriate management personne The NRC inspector observed and/or reviewed the documentation for the following surveillance test activities. The procedures used for the test activities are noted in parenthesi . Station battery chargers monthly check (ST-DC-2-F.1)

. Emergency diesel generator (D-1) monthly check (ST-ESF-6-F.2)

. Control element assembly biweekly check (ST-CEA-1-F.4)

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. Component cooling water category B valve quarterly check (ST-ISI-CC-1-F.1)

. Emergency diesel generator (0-2) monthly check (ST-ESF-6-F.2)

No violations or deviations were identifie . Security Observations The NRC inspector verified the physical security plan was being implemented by selected observation of the following items:

. The security organization is properly manne . Personnel within the protected area (PA) display their identification badge . Vehicles are properly authorized, searched, and escorted or controlled within the P . Persons and packages are properly cleared and checked before entry into the PA is permitte . The effectiveness of the security program is maintained when security equipment failure or impairment requires compensatory measures to be employe During this inspection, the NRC inspector noted that safeguards information was not properly controlled and that an electrical one-line diagram was not properly identified as safeguards information. The discussion of these apparent violations contains safeguards information, as defined in 10 CFR Part 73.21; therefore, the details of these apparent violations are presented in Appendix A and Attachment of this inspection repor On September 11, 1986, the licensee experienced problems with the security emergency diesel generator (EDG). The automatic transfer switch (ATS)

which transfers the site security electrical loads from the normal ac power supply to the EDG supply, failed due to arcing of mechanical contacts in the ATS. This failure caused the loss of the normal ac supply to security electrical loads. The EDG was started and picked up the security electrical loads. A short while later the EDG was secured for repair of the ATS. An evaluation of the ATS indicated that due to burnt contacts and wire termination lugs, the ATS could not be repaire Approximately 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> later, the EDG was again started to supply the security electrical loads. The diesel continued to supply the electrical loads until temporary ac power was supplied to the electrical bus on September 16, 1986. The ac power was installed to bypass the ATS and apply ac power directly to the security electrical loads. The output of the EDG was also altered so that the output bypassed the AT During the REMOVAL OF THE PAGES MARKED " "

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time that the ATS was bypassed, two electricians were maintained onsite around-the-clock to manually start the EDG in the event the temporary ac power source was los The licensee procured and installed a new ATS. When installation of the ATS was completed, the temporary ac power source was disconnected and the electrical system returned to normal. Tests were performed to verify the proper functioning of the normal and emergency power sources to the security electrical load During the operation of the EDG from September 11 to September 16, the licensee experienced difficulty with the EDG being able to supply the necessary output power for the security electrical loads. At one point during this time period, the EDG tripped off the line due to clogged intake air filter on the engine. The onduty electricians removed the air filter and immediately restarted the EDG. The licensee performed an evaluation to determine the cause of the clogging of the air filters but has yet to determine the exact cause. The licensee feels that the most probable cause is the location of the exhaust piping. If the EDG is operating with the wind blowing towards the north, the EDG exhaust gasses are blown into the area where the engine fresh air intake is located. The licensee is continuing to evaluate the problem. This is an open item pending determination of the problem and performance of the necessary corrections. (285/8623-03)

As an interim measure, the licensee has notified the appropriate personnel to monitor the status of the air filter during operation of the ED If the filter starts to become clogged, these personnel have been instructed to remove and re place the air filter during EDG operatio The NRC resident inspector reviewed the preventive maintenance (PM)

activities performed by the licensee on the EDG. This review was performed to verify that the licensee was providing proper preventive maintenance on the EDG. The review determined that the licensee had established and performed PM activities on the EDG in accordance with manufacturer instructions. No problems were noted during this revie At various times during this event, power was lost to the security electrical loads which required the licensee to take appropriate compensatory actions. The actions taken by the licensee were reviewed onsite by an NRC inspector from the Region IV Security and Safeguards Section. The review performed by the NRC security inspector determined that the licensee had taken proper and timely compensatory actions while the power was lost to the security system electrical load . Management Organizational Changes On September 1, 1986, the licensee implemented organizational changes affecting the training and emergency planning departments, and added a new group to the plant organization. Under the new organization, the training department which previously reported to the Manager - Fort Calhoun REMOVAL OF THE PAGES MARKED " "

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Station, now reports to the Manager of Administrative Services. The emergency planning group which previously reported to the Manager of Administrative Services, now reports to the Manager of Technical Service A new planning and scheduling group has been established onsite and this group reports to the Manager - Fort Calhoun Statio The organization chart provided in Figure 5-2 of Section 5 to the TS and the chart provided in Figure 1 of Section 1.2 of the licensee's Quality Assurance Manual (QAM) have not been updated to reflect the new organizational changes. The licensee has performed an evaluation and has determined that the organizational changes made do not lessen the requirements shown in the TS or QAM. However, the licensee has not yet submitted, for NRC approval, revisions to the TS or QAM to reflect the organizational changes. This itein remains unresolved pending submission of the appropriate changes by the licensee and NRC staff review and approvals of the submittal. (285/8623-04)

12. Unresolved Item An unresolved item is a matter about which more information is required in order to determine whether it is acceptable, a violation, or a deviatio One unresolved item is discussed in paragraph 1 . Exit Interview The NRC inspector met with Mr. R. L. Andrews (Division Manager - Nuclear Production Division) and other members of the OPPD staff at the end of this inspection. At this meeting, the NRC inspector sumarized the scope of the inspection and the finding REMOVAL OF THE PAGES MARKED " SAFEGUARDS INFORMATK]N" DECONTROLS THE REMAINDER OF THIS DOCUMENT.