IR 05000295/1993015
| ML20057B840 | |
| Person / Time | |
|---|---|
| Site: | Zion File:ZionSolutions icon.png |
| Issue date: | 09/10/1993 |
| From: | Farber M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20057B833 | List: |
| References | |
| 50-295-93-15, 50-304-93-15, NUDOCS 9309240056 | |
| Download: ML20057B840 (12) | |
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U.S. NUCLEAR REGULATORY COMMISSION
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REGION III
Report tios. 50-295/93015(DRP); 50-304/93015(DRP)
Docket Hos. 50-295; 50-304 License Nos. DPR-39; DPR-48
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Licensee:
Commonwealth Edison Company t
Executive Towers West III
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1400 Opus' Place - Suite 300 Downers Grove, IL 60515
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Facility Name:
Zion Nuclear Power Station, Units 1 and 2 Inspection At:
Zion, IL
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inspection Conducted: July 21 through September 1, 1993
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Inspectors:
J. D. Smith V. P. Lougheed
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M. J. Miller
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M. A. Shuaibi R. B. Landsman
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. Approved By:
1 J Far N
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Reactor Projects Section IA Dat'e /
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Inspection Summarv i
Inspection from Julv 21 to September 1.1993 (Report No. 50-295/304-93015(DRP))
Areas Inspected: This was a routine, resident inspection of licensee action on previous inspection findings; summary of operations; operational safety verification and engineered safety feature system walkdown; maintenance and surveillance observation; engineering and tachnical support observations; safety assessment and quality verification; licensee event reports (LERs); and management meetings.
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9309240056 930914
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DR ADDCK 05000295 PDRw.
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Plant Operations Licensee response to several minor events, occurring within a two day period,
was appropriate. The inspectors considered the events to be isolated, and not i
indicative of the licensee's overall performance.
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Maintenance and Surveillance Increased management attention and expectations for daily work planninr, are
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showing improvements as illustrated by the work completed on schedule.
The
turbocharger replacement on the 1A diesel generator was well scheduleo and i
executed.
Enoineerino and Technical Specifications
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The system engineers' ability to troubleshoot and recover the Eagle 21 l
protection system failures has been good. However, vendor support in the area
of root cause analysis has been unsatisfactory. Management attention is being focused on vendor support concerns. Technical staff engineering support was
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good.
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Safety Assessment and Quality Verification The QC program's effectiveness review by the residents found the personnel to be well qualified and prepared for their inspection tasks.
They performed
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thorough field inspections. However, minor weaknesses were found in QC plant tours and field time, j
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DETAILS r
1.
Persons Contacted R. Tuetken, Vice President, Zion Station
- A. Broccolo, Station Manager M. Lohmann, Site Engineer & Construction Manager
- P. LeBlond, Executive Assistant
- S. Kaplan, Regulatory Assurance Supervisor D..Wozniak, Technical Services Superintendent
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- L. Simon, Maintenance Supervisor
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J. LaFontaine, Outage Management Manger i
T. Printz, Assistant Superintendent of Operations
- R. Cascarano, Services Director
- W. Stone, Performance Improvement Director
- K Moser, Assistant Technical Staff Supervisor
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R. Milne, Security Administrator P. Cantwell, Unit 2 Operating Engineer l
W. T'Niemi, Unit 1 Operating Engineer K. Hansing, Unit 0 Operating Engineer
D. Bump, Quality Verification Supervisor
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- K. Dickerson, Regulatory Assurance - NRC Coordinator
- Indicates persons present at the exit interview on September 1, 1993.
The inspectors also contacted other licensee personnel including members J
of the operating, maintenance, security, and engineering staff.
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i 2.
Licensee Actions on Previous Inspection Findinas (92701. 92702)
a.
(Closed) Inspection Followuo item (295/88015-01(DRSI):
" Complete i
Commitment to Determine the Cause of the Main Steam Safety Valves Setpoint Being Out of Tolerance." The licensee switched from testing the valves with nitrogen to testing tham with steam.
Additionally, the maintenance procedure was revised to ensure
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that, following maintenance, the valve setpoints were within a one percent band. These corrective actions were successful, as shown by over five years of operation without repetitive safety valve failures. This item is closed.
b.
(Closed) Inspection Followup Item (295/304-90030-15(DRP)):
" Molded Case Circuit Breaker (MCCB) Testing." The licensee developed a program for periodically testing MCCBs. Testing of the in-place MCCBs was progressing satisfactorily. This item is closed.
c.
(Closed) Unresolved Item (295/304-90030-28(DRP)):
" Air in the
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Component Cooling Water Heat Exchangers." The concerns expressed in this unresolved item are also being tracked by inspection followup items 295/90030-03, 90030-09, and 91012-01.
Modifications to the component cooling water system are planned for the September 1993 dual unit outage. As these modifications
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I are adequately tracked by the followup items and no violation was identified, this unresolved item is considered closed.
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d.
JClosed) Inspection Followup Item (295/91010-07(DRP)):
" Poor Prioritization of Parts Evaluations." The inspectors reviewed the
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licensee's procedures for prioritization of parts and sampled recent evaluations. The inspectors concluded that problems
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discussed in the inspection followup item appeared to have been
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resolved.
This item is closed.
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(Closed) Inspection Followup Item (295/91012-02(DRP)):
" Lack of j
Attention to Detail Trend Observed." This item documented five
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events caused or exacerbated by lack of attention to detail. The
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licensee has made significant strides in reducing personnel errors. This item is closed.
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f.
(Closed) Unresolved Item (304/91012-01(DRP)):
" Control of the Administrative Out-of-Service to Ensure Room Cooler Operability
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for the Containment Spray Pump Room." The licensee has continued to make progress on control of out-of-services.
The residents
will continue to monitor the out-of-service process This item is closed.
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(Closed) Unresolved item (304/91020-01(DRP)):
" Missed Post i
Maintenance Test." The inspector reviewed the licensee's actions t
in response to the failure to perform a post maintenance verification test for the containment air space sample isolation r
valve, 2FCV-PR19B, prior to declaring the valve operable. The
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licensee trained all licensed, and non-licensed shift personnel on
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the self check program and emphasized the importance of paying
attention to detail and verifying equipment numbers. The
inspector had no concerns with-the licensee's corrective actions.
This item is closed.
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(Closed) Inspection Followup Item (304/91020-02(DRP)): " Concerns
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on Maintenance of the 2A Auxiliary feedwater Pump." The inspectors reviewed the licensee's corrective actions, which
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included procedure revisions and system modifications.
This item
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is closed.
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(Closed) Inspection Followup Item (295/91026-03(DRP)):
" Loss of
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Bus 142/147 by OAD."
Prior corrective actions to control switchyard work by non-station personnel included meetings with
the appropriate personnel from substation construction and the i
operational analysis department (OAD) to establish communication i
and control mechanisms for scheduling switchyard work.
Due to the
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recurrent problems, the station took further controlled switchyard
l evolutions by locking all access to the yard and relay house and requiring permission for entry to be obtained from the operating shift supervision. This item is closed.
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(Closed) Insnection Followup Item (295/91026-04(DRP)):
" Minor
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Events from Lack of Attention to Detail." This item documented five additional events caused or exacerbated by lack of attention to detail. The licensee has made significant strides in reducing personnel errors. This item is closed.
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(Closed) Violation (295/91027-02(DRP)):
" Inoperable Batteries Due to Inoperable Exhaust Fans." Station personnel recognized that procedure PT-14, " Inoperable Equipment Surveillance" was cumbersome and difficult to use. The procedure was revised and personnel were trained on the revision. An effectiveness evaluation was performed three months after issuance of the revision and confirmed that the.necessary changes had been made.
The training department also revised the computer and miscellaneous rooms HVAC system training material to include more j
detailed information on battery room ventilation systems. This i
violation was reviewed with all licensed operators.
Furthermore, the station issued the Zion operability determination manual (ZODM) to provide a standard for (1) evaluating the operability of failed, degraded, or deficient equipment; (2) identifying the equipment's safety functions; and (3) evaluating operability due to surveillance testing.
In addition, the root cause committee reviewed the operating logs on a daily basis to ensure that issues requiring further investigation are identified.
This violation is closed.
1.
(Closed) Inspection Followup item (304/92004-02(DRP)):
" Inoperable Containment Isolation Valve." This item was discussed in Inspection Report 295/304-93008: the discussion was correct; however, the wrong unit was cited. The Unit 2 item is closed.
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(Closed) Inspection Followun item (295/92010-02 (DRP)):
"Possible l
flooding of 480 VAC Motor Control Center (MCC)." The licensee i
analyzed three scenarios:
rupture of the fire header due to a i
seismic event, leakage from the fire header due to erosion / corrosion, and leakage through unsealed penetrations from the floor above. The licensee's analysis found that there was an
" extremely low probability" of the motor control center flooding, I.
and that corrective actions were not necessary. This item is l
closed, n.
(Closed) Violation (304/92022-Ol(DRP)):
" Loss of Shutdown Cooling and Inadvertent Spray in Containment." The licensee trained the operators on effective communication skills; reviewed all RHR periodic testing (PT) procedures; changed several pts to ensure that relevant information was included; took steps to eliminate partial surveillances; and emphasized procedural adherence during requalification of operators. The inspectors have no concerns with the licensee's corrective actions. This item is closed.
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(Closed) Violation (295/92031-01 (DRP)):
" Failure to verify l
position of AFW pump discharge valve." An improper independent
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line-up verification during valve realignment resulted in a mis-positioned motor-driven auxiliary feedwater pump discharge valve.
l Procedures were revised to require running both motor-driven pumps
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and verifying flow to each steam generator when realigning j
headers. This event was also included in training discussions.
This item is closed.
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(Closed) Violation (295/304-92035-01(DRP)):
" Inaccurate Information on Work Experience of Supervisor." Further
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investigation, by both the licensee and the NRC, determined that i
the supervisor in question had sufficient experience to meet the
position requirements. The Zion administrative procedure on j
personnel qualifications (ZAP 5-51-19) was modified to ensure that-
accurate personnel qualification records were maintained and l
reviewed prior to promoting or transferring a person into a
position requiring ANSI certification. The inspectors have no i
concerns regarding these corrective actions. This item is closed.
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(Closed) Unres_plved Jtem (295/304-93014-03(DRP)):
" Corrective l
Actions for the Technical Supcort Center's (TSCs) Emergency Makeup l
Air Treatment System Being Found Mis-positioned." The inspectors
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reviewed the licensee's actions in response to the concerns.
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licensee completed _ reviews of procedures for other radiation j
monitors and changes are being made to ensure procedural clarity.
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The licensee also placed signs reading " AUTHORIZED ENTRY ONLY, l
TECH. SPEC. RELATED EQUIP." on the doors leading to the control
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panel room in the TSC. The inspectors have no concerns with the licar e's corrective actions and this item is closed.
T No violati m or deviations were identified.
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3.
Summary of Operations
Unit 1 l
The unit remained at approximately 100 percent power throughout the
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report period.
Unit 2 The unit operated in the load-following mode between 50 to 100 percent power for the entire report period.
No violations or deviations were identified.
4.
Operational Safety Verification and Enaineered Safety Features System Walkdow" (71707 & 71710)
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The inspectors verified that the facility was being operated in conformance with the licenses and regulatory requirements and that the
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licensee's management control system was effectively carrying out its s
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responsibilities for safe operation.
During tours of accessible areas of the plant, the inspectors made note of general plant and equipment conditions, including control of activities in progress.
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On a sampling basis, the inspectors observed control room staffing and coordination of plant activities; observed operator adherence with procedures and technical specifications; monitored control room indications for abnormalities; verified that electrical power was available and observed the frequency of plant and control room visits by station managers.
The inspectors also monitored various administrative i
and operating. records.
l The specific areas observed were:
Enaineered Safety Features (ESF) Systems
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Accessible portions of ESF systems and their support systems components were inspected to verify operability through observation of instrumentation and proper valve and electrical power alignment. The inspectors also visually inspected components for material conditions. While touring the auxiliary
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building, the inspector identified a safety-related pipe support with a loose anchor bolt. The issue was brought to the licensee's
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attention and a work request was initiated.
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Radiation Protection Controls
The inspectors verified that workers were following health physics procedures and randomly examined radiation protection
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instrumentation for operability and calibration.
Security
During the inspection period, the inspectors monitored the licensee's security program to ensure that observed actions were being implemented according to their approved security plan.
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Housekeepina and Plant Cleanliness
The inspectors monitored the status of housekeeping and plant cleanliness for fire protection and protection of safety-related equipment from intrusion of foreign matter.
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a.
Operational Events r
Minor Events Due to a lack of Attention to Detail:
During this
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inspection period, several minor events occurred within a two day period. The events were documented through the licensee's problem identification form program, root cause investigations were
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initiated, and appropriate corrective actions were taken. These
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actions included a discussion with all the operating shifts by the assistant superintendent of operations as to expectations for i
attention to detail and procedural adherence.
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Similar cases of." lack of attention to detail" occurred during
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1991 and again late in 1992.
In response to the 1991 events, the
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licensee initiated the " STAR (stop, think, act review) program" to
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ensure that all station personnel paid attention to detail.
Additionally, station management has emphasized the need for
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continuing attention to detail. These actions resulted in a i
significant reduction in personnel errors over the last two years.
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b.
Assessment of Plant Onerations Licensee response to several minor events, occurring within a two
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day period, was appropriate. The inspectors considered the event s j
to be isolated, and not indicative of the licensee's overall
performance.
No violations or deviations were identified.
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5.
Monthly Maintenance and Surveillance (62703 and 61726)
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Routinely, station maintenance and surveillance activities were observed
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or reviewed to ensure that they were conducted in accordance with
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approved procedures, regulatory guides and industry codes or standards,
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and in conformance with technical specifications.
The following items were also considered during this review: that approvals were obtained prior to initiating the work and testing, and i
that operability requirements were met during such activities; that
.i functional testing and ' calibrations were performed prior to declaring j
the component operable; that any discrepancies identified during the
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ar.tivities were resolved prior to returning the component to service;
that quality control records were maintained; and that activities were
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accomplished by qualified personnel.
a.
Maintenance / Surveillance Related Activities Containment Snray (CS) Pump IC:
The diesel driven CS pump continued to have problems starting during the biweekly surveillances.
The problem appeared to be air inleakage into the fuel system.
During this inspection period, 'he lice e
l confirmed the presence of air in the fuel system w.d continued
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trouble-shooting efforts to identify the source of the inleakage.
A loose elbow, with a missing gasket, was identified and repaired.
The vendor was contacted and a representative was brought onsite to help with the trouble-shooting.
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fleplacement of the 1A Diesel Generator Turbocharaer: The 1A l
_diesel generator (DG) had been losing jacket water while operating i
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at full load.
Following significant troubleshooting, the problem
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I was identified as being a flange gasket leak between the turbocharger exhaust side and the ;acket water.
The flange was
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retorqued and the leak ceased for a short time. The leak returned l
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the following week during periodic testing. Although the DG was considered operable, the station elected to change out the i
turbocharger. A 72 hour8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> limiting condition for operation (LCO)
was entered and the work was accomplished in a controlled manner.
The only significant delay was a minor voltage regulator problem.
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Electrical maintenance promptly corrected the problem and the DG was returned to service well within the LC0 time requirement.
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b.
Assessment of Maintenance and Surveillance
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Increased management attention and expectations for daily work
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planning is showing improvements as illustrated by the work completed on schedule. The turbocharger replacement on the 1A diesel generator was well scheduled and executed.
No violations of deviations were identified.
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Enaineerina and Technical Support (37828)
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The inspectors evaluated the extent to which engineering principles and evaluations were integrated into daily plant activities.
This was accomplished by assessing the technical staff involvement in non-routine events, outage-related activities, and assigned TS surveillances; observing on-going maintenance work and troubleshooting; and reviewing deviation investigations and root cause determinations.
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a.
Engineering and Technical Support Events Eaale 21 Snoradic Alarms:
Sporadic alarms of the Eagle 21 process protection system for both units have continued through the report period.
No additional progress has been made in identifying the cause of the alarms. Circuit cards identified by the station as a source of some of the spurious alarms were sent to the vendor for root cause failure analysis. To date the vendor has not provided
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the station with those analysis.
On August 15,1993, a 15 volt power supply failed on Unit 1, Set 1.
Unit I has had a total of four power supply failures {the 15 volt _section) in the past 9 months. There have been no additional f ailures with the replaced power supplies.
On August 26, 1993, the loop calculator processor circuit board for Unit 1, Protection Set I locked up and required replacement.
On August 31, 1993, the Eagle partial trip circuit board on Unit 1, Protection Set 1 indicated a partial trip on high steam flow.
The circuit card required replacement.
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In addition to the above failures in Protection Set 1, the
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following circuit cards have been replaced in Protection Set I due
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to failures:
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4/23/93 Tester Subsystem Processor Data Link Handler 6/21/93 Tester Subsystem Processor 7/24/93 Loop Calculator Processor Data Link Handler
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the immediate problem. However, the vendor has not provided.
follow up root cause analysis of the failed circuit cards to aid
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in improving the reliability of the system.
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b.
Assessment of Engineering and Technical Support i
The system engineers' ability to troubleshoot and recover the Eagle 21 protection system failures has been good.
However, vendor support in the area of root cause analysis has been unsatisfactory. Management attention is being focused on vendor support concerns.
Technical staff engineering support was good.
No violations or deviations were identified.
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Safety Assessment and Quality Verification (40500)
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The effectiveness of management controls, verification and oversight activities in the conduct of jobs observed during this inspection were evaluated. Management and supervisory meetings involving plant status
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were attended to observe the coordination between departments.
The results of licensee corrective action programs were routinely monitored by attendance at meetings, discussion with the plant staff, review of i
deviation reports, and root cause evaluation reports.
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a.
Quality Control Program An inspection of the licensee's quality control (QC) program was
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conducted.
During the inspection, the inspectors reviewed QC documentation including monthly reports, modification group reviews, significant operating experience report effectiveness reviews, and QC surveillance documents; interviewed several QC i
personnel; and accompanied QC personnel on field inspections and plant tours.
The licensee's QC personnel did thorough field inspections. They checked for quality assurance tags on parts, verified tag numbers with numbers on receipts, ensured that jobs were done according to procedures, and interrupted work at different points to inspect for quality. QC personnel came to the jobs prepared with procedures and drawings, which they had obviously studied, and the required tools needed for inspections.
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o However, the thoroughness of the field inspections did not appear to extend to the general plant tours. QC personnel intended the tours to cover areas where work was ongoing or where previous l
deficiencies were identified. The tours were general in nature,
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with an emphasis on housekeeping and control of tools. The j
inspectors explained how NRC tours were performed, and drew
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attention to items the inspectors had previously identified, such
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as loose hangers and missing bolts.
Additionally, the inspectors reviewed the amount of time that QC inspectors spent inside the vital area.
Based on plant access records, it was determined that QC personnel spent-approximately
ten hours inside the station's vital area. Although this review did not include QC responsibilities outside of the vital area,
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such as receipt inspections, the inspectors perceived that QC personnel field time could be improved. The inspectors noted that the QC supervi.sor had a goal to increase QC field time.
b.
Assessment of SAQV The QC program's effectiveness review by the residents found the personnel to be well qualified and prepared for their inspection
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tasks. They performed thorough field inspections.
However, minor weaknesses were found in QC plant tours and field time.
No violations or deviations were identified.
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8.
Licensee Event Reports (LERs) followup (92700)
l Through direct observations, discussions with licensee personnel, and
review of records, the following event reports were reviewed to determine that reportability requirements were fulfilled, immediate corrective action was accomplished, and corrective action to prevent i
recurrence had been accomplished in accordance with technical
specification requirements.
The LERs listed below are considered
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closed:
LER NO.
DESCRIPTION
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295/93019-01 Autostart of Engineered Safety features Components During Safeguards Testing: This supplemental LER provided additional information on the root cause of
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the event.
The inspectors had no concerns with the supplemental report.
i 295/93007 Unit 1 Reactor Trip due to a shorted terminal on a Loop Stop Isolation Valve Limit Switch: This event i
was reviewed in Inspection Report 93014. The inspectors have no further concerns on the LER.
No violations or deviations were identified, l
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9.
Report Review During the inspection period, the inspectors reviewed the licensee's monthly performance report for July 1993. The inspector confirmed that the information provided met the requirements of Technical Specification 6.6.1.E and Regulatory Guide 1.16.
The inspectors also reviewed the licensee's monthly plant status report for July 1993.
No violations or deviations were identified.
10.
Manaaement Meetinas (30703)
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On August 5 and 6, Mr. John B. Martin, Region III Regional Administrator, toured the site and interviewed senior management.
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portions of the improvement program reviewed were considered to be
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progressing satisfactorily.
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11.
Manaaement Channes On August 10, 1993, Mr. Anthony E. Broccolo was named as the new Statien Manager.
In addition, Mr. Broccolo will continue to act as Operations Manager until a replacement can be selected.
12.
Exit Interview (30703)
The inspectors met with licensee representatives (denoted in section 1)
throughout the inspection period and at the conclusion of the' inspection on September 1, 1993, to summarize the scope and findings of the inspection activities. The licensee acknowledged the inspectors'
comments.
The inspectors 'also discussed the likely informational content of the inspection report with regard to documents or processes reviewed by the inspectors during the inspection. The licensee did not identify any such documents or processes as proprietary.
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