IR 05000313/1985013

Insp Repts 50-313/85-13 & 50-368/85-13 on 850501-31. Violations Noted:Fire Doors Left Open & Inadequate Emergency & Abnormal Procedure Reviews by Licensed Operators

ML20127L975
Person / Time
Site:	Arkansas Nuclear
Issue date:	06/26/1985
From:	Harrell P, Johnson W, Martin L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20127L947	List: IR 05000313/1985013 ML20127L942 ML20127L961
References
50-313-85-13, 50-368-85-13, IEB-84-02, IEB-84-03, IEB-84-2, IEB-84-3, NUDOCS 8507010026
Download: ML20127L975 (13)

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APPENDIX B U. S. NUCLEAR REGULATORY COMMISSION

REGION IV

NRC Inspection Report: 50-313/85-13 Licenses: DPR-51 50-368/85-13 NPF-6 Dockets: 50-313 50-368 Licensee: Arkansas Power and Light Company (AP&L)

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P. O. Box 551 Little Rock, Arkansas 72203 Facility Name: Arkansas Nuclear One (ANO), Units 1 and 2 Inspection At: ANO Site, Russellville, Arkansas Inspection Conducted: May 1-31, 1985 Inspectors: M 8 ddIv//S W."D.~Johnsopf Senior Resident D6te/

Reactor Inspector (pars. 1, 3, 4, 5, 6, 7, 8)

h/ l A P."H' Harrb y Resident Reactor Baty~

Inspector (pars. 1, 2, 5, 6, 7, 8, 9)

Accompanying Personnel:

G. S. Vissing, Project tianager, Operating Reactor Branch 4 Approved: /3

~ LI E. Martin'vChief, Reactor

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X Project Section 2A Inspection Summary Inspection Conducted May 1-31, 1985 (Report 50-313/85-13)

Areas Inspected: Routine, unannounced inspection including operational safety verification, maintenance observations, surveillance, operator requalification training, maintenance records review, followup on previously identified items, and followup on IE Bulletin The inspection involved 76 inspector-hours (including 7 backshift hours) onsite by two NRC inspector DR ADOCK 0500

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Results: Within the seven areas inspected, no violations were identifie Inspection Summary Inspection Conducted May 1-31, 1985 (Report 50-368/85-13)

l Areas Inspected: Routine, unannounced inspection including operational safety verification, maintenance observations, surveillance, operator requalification training, maintenance records review, followup on previously identified items, followup on IE Bulletins, and followup on licensee event report The inspection involved 95 inspector-hours (including 9 backshift hours) onsite by two NRC inspector Results: Within the_efght areas inspected, two violations were identified

(fire doors left open, paragraph 5, and inadequate emergency and abnormal j procedure reviews by licensed operators, paragraph 9).

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DETAILS l '1. Persons Contacted

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• J. Levine, ANO General Manager

! *B. Baker, Operations Manager i

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D. Bennett, Mechanical Engineer M. Bolanis, Health Physics Superintendent M. Browning, Maintenance Engineer

• P. Campbell _, Licensing Engineer

• T. Cogburn, Special Projects Manager J. Constantin, Unit 2 Operations Trainer M. Coombs, Civil Engineer l *L. Dugger, Acting I&C Maintenance Superintendent i E. Ewing, Engineering & Technical Support Manager E. Force, Unit 1 0- ations Training Supervisor L. Gulick, Unit . arations Superintendent D. Hamblen, Quality Control Engineer i R. Hargrove, Unit 2 Classroom Lead Trainer 1

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G. Helmick, Planning & Scheduling Supervisor H. Hollis, Security Coordinator

• L. Humphrey, Administrative Manager

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P. Kearney, Mechanical Engineer

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J. Lamb, Safety and Fire Protection Coordinator *D. Lomax, Licensing Supervisor B. McCord,-Planning and Scheduling Coordinator

! J. McWilliams, Unit 1 Operations Superintendent i

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J. Montgomery, Human Resources Supervisor *M. Pendergrass, Acting Engineering & Technical Support Manager l

V. Pettus, Mechanical Maintenance Superintendent *D. Provencher, Quality l Engineering Supervisor l R. Rispoli, Fire Protection Specialist P. Rogers, Plant Licensing Engineer D. Russell, Electrical Engineer l L. Sanders, Maintenance Manager l *L. Schempp, Nuclear Quality Control Manager *C. Shively, Plant Engineering Superintendent

• R. Simmons, Planning and Scheduling Supervisor *G. Storey, Safety and Fire Protection Coordinator l L. Taylor. Operations Technical Engineer R. Tucker, Electrical Maintenance Superintendent i R. Turner, Electrical Engineering Supervisor *J. Vandergrift, Training Superintendent

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D. Wagner, llealth Physics Supervisor l B. West, Instrumentation and Controls Supervisor

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D. Whiting, Mechanical Maintenance Supervisor I G. Wrightam, Instrumentation and Controls Supervisor i C. Zimmerman, Operations Technical Support j *Present at exit interview.

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.. ' The.; inspectors also coritact'ed 'other plant personne,1,fnclhding operators, #

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techn , .~,icians,

and_ administrative

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2.* . Foll'owup'on Previou3 ,y Identified Items (Units 1 and 2)

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7, 4 (C]osed) Open It,ue313'/8504-02; 368/8504-03: Revision of the 1985\

f f quality assurpnce.(QA) audit schedul ,

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L t 6-/ - klicenseehasrevisedthe1985-QAauditscheduletoinclude

~ ~ previously omitted. audits required by Technical Specification l6.5.2.8.' The audit sl:hedule now appears to be complete and meets-the Technical Specification audit requirement , .,/ <.

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(C40 sed)' Cpen Item 313/8504-04; 368/8504-05: Revision of audit g .checxlist QAP-9. -

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The:ltcensee has revised the QAP-9 audit checklist to require

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.w 'thst alreview be performed to specifically address the use of

'sipervisofsasdesignverifier In addition, the licensee has ( required t. hat futste audit reports written in this area include a specific-discussion of the audit results of the use of

- ,stpervisdis 'as design ' verifier y :. .

(CTosed) ~ Open Item 31378504-05; 368/8504-06:

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Form used for the audit schedul a . -

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%U Tiie licensee reviewed the audit scheoule format form specified J%yjf , e_O by, the proce'duYe and the form currently in use by the QA organ-

'Y fiation. 3Thotreview concluded that the more detailed form used by the QA-organization would be required for the preparation of

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., future audit schedule , .l+ i . . .

<4 + ~~(Closed) Open Item 313/0504-06; 368/8504-07: Inclusion of checklist

. .g y rmtision' numbers in audit report yp y The licensee now requires that the revision number of the

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5 fchecklist used to perform an audit be included in the audit

, Y ' repor Ose of the revision number will ensure adequate

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, ' Licence'e' Event Report (LER) Followup (Unit 2)

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'"Thrdujhdirectt obst.rvation, discussions with licensee personnel, and

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. + . review'ol~reco'rds, the following Unit 2 event reports were reviewed to

#n' determine.that reportability requirements were fulfilled, immediate M,1*Q'

?, . 4-J corfectivu action was accomplished,'and corrective action to prevent P (* - recurrihce has been accomplished in accordance with Technical

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%., d , 81-017/01T-1 , 83-025/01T-0 h

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% A21001/01T-0

/G3,009/01T-0 84-009-00 84-025-00

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. 83-014101T-0

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-4-These LERs reported calibration or time response degradation problems with reactor coolant system resistance temperature detectors (RTDs). The cause of the time response degradation was determined to be the degradation of the couplant used to mate the RTD and the thermowel The licensee has replaced the RTDs with a model made by the Weed Instrument Compan This model is designed such that no couplant should normally be require Prior to replacement of- the RTDs, the thermowells were thoroughly cleane The licensee is continuing to-monitor the time response of the RTDs monthl No violations or deviations were identifie . Followup on IE Bulletins (Units 1 and 2) IE Bulletin 84-03 This bulletin, entitled " Refueling Cavity Water Seal," was issued on August 24, 198 The licensee provided written responses to the bulletin, as required, in letters dated October 16, 1984, and November 26, 1984, for Units 1 and 2, respectively. Tnese responses covered the following key points:

. The ANO units do not use a pneumatic seal as a portion of the reactor cavity water seal and thus are not subject to a failure similar to the one described in the bulleti .

The ANO seal plates are annular plates made of stainless steel, held in place with bolts or studs, and sealed with rubber gasket .

Potential for leakage past the gaskets exists and leakage has been observed, but it was estimated at less than 10 gallons per minut . There are procedures in place for handling any such leakag . Analysis indicated that plate gross failure could not be caused by dropping a fuel assembly on the seal plat . If the water in the spent fuel pool were drained to the level of the reactor vessel flange, the active height of fuel in the spent fuel pool would remain covere The NRC inspector reviewed the above responses, reviewed associated procedures and drawings, and observed seal plate operations during the recent refueling outages for Units 1 and 2. The emergency procedures for transfer canal seal plate gasket failure are provided as attachments to the refueling shuffle procedures.

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-5-No violations or deviations were identifie The NRC inspector's review of this bulletin is complet IE Bulletin 84-02 This bulletin, entitled " Failures of General Electric Type HFA Relays in use in Class 1E Safety Systems," was issued on March 12, 198 The licensee provided written responses to this bulletin in letters dated July 20, 1984, and February 11, 198 The licensee found that they had 102 relays of the type described in the bulletin installed in safety-related systems. The licensee implemented a program for inspection of these relays and also those

'in nonsafety-related systems. Some of the inspections were witnessed by the NRC inspector. During the recent refueling outages, the licensee replaced the HFA relays in safety-related systems with new h General Electric Century series relays. The NRC inspector reviewed the completed job orders for this replacement.

l The licensee's response informed the NRC of a similar problem experienced with Potter & Brumfield (P&B) model MDR 137-8 and MDR 138-8 relays in Unit 2. The P&B relays were replaced by new P&B relays of like kind in both the third and fourth refueling outage During the fifth refueling outage, the licensee plans to replace the

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P&B relays with an improved model which is being developed and tested by P&B.

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No violations or deviations were identified. The NRC inspector's review of this bulletin is complete for Unit 1, but this bulletin remains open for Unit 2 pending replacement of the P&B relay . Operational Safety Verification (Units 1 and 2)

The NRC inspectors observed control room operations, reviewed applicable logs, and conducted discussions with control room operators. The l inspectors verified the operability of selected emergency systems, j reviewed tagout records, verified proper return to service of affected components, and ensured that maintenance requests had been initiated for equipment in need of maintenance. The inspectors, by observation and direct interview, verified that the physical security plan was being implemented in accordance with the station security plan. The inspectors l Verified implementation of radiation protection controls during plant i activities.

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l The NRC inspectors toured accessible areas of the units to observe plant equipment conditions, including potential fire hazards, fluid leaks, and excessive vibration. The inspectors also observed plant housekeeping and cleanliness conditions during the tour. It was noted to licensee

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h personnel that the 404 elevation in Unit 2 needed additional housekeeping l' attention. The licensee cleaned up the identified area immediately. The p NRC inspectors also informed licensee personnel that the Unit 2 upper

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north piping penetration room needed additional housekeeping attention.

. During a tour of the Unit 2 auxiliary building on May 18, 1985, the NRC inspector found two fire doors ajar on two occasions each. These doors lead from the main auxiliary building stairway to elevations 335 and 354 and are numbered 213 and 235, respectivel The NRC inspector shut the doors each time they were found ajar. The doors had to be shut by hand l since the automatic door closers were not powerful enough to overcome the l air flow through the doors. The licensee's failure to maintain these l doors shut is a violation of Technical Specification 3.7.1 (368/8513-01)

The NRC inspectors walked down the accessible portions of the Unit 2 containment spray system. The walkdown was performed using Procedure l 2104.05 and Drawing M-2236. During the walkdown, the NRC inspectors noted that two valve numbers provided on the valve lineup did

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not agree with the valve numbers shown on the drawing or the tags installed on the valves. Licensee personnel stated the discrepancies would be correcte These reviews and observations were conducted to verify that facility operations were in conformance with the requirements established under Technical Specifications, 10 CFR, and administrative procedure . Monthly Surveillance Observation (Units 1 and 2)

l- The NRC inspectors observed the Technical Specification required surveillance testing on the Unit 1 station battery (Procedure 1307.16)

and verified that testing was performed in accordance with adequate procedures, test instrumentation was calibrated, limiting

- conditions for operation were met, removal and restoration of the affected components were accomplished, test results conformed with Technical Specification and procedure requirements, test results were reviewed by

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personnel other than the individual directing the test, and any deficiencies identified during the testing were properly reviewed and resolved by appropriate management personne The inspectors also witnessed portions of the following test activities:

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Unit 2 diesel generator 18-month operational test (Procedure 2103.26, Supplement 4)

i . Unit 2 charging pump monthly test (Procedure 2104.02)

. Unit 2 service water pump monthly test (Procedure 2104.29)

No violations or deviations were identified.

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-7- Monthly Maintenance Observation (Units 1 and 2)

Station maintenance activities of safety-related systems and components listed below were observed to ascertain that they were conducted in accordance with approved procedures, Regulatory Guides, and industry codes and standards; and in conformance with Technical Specification The following items were considered during this review: the limiting conditions for operation were met while components or systems were removed from service; approvals were obtained prior to initiating the work; activities were accomplished using approved procedures and were inspected as applicable; functional testing and/or calibrations were performed prior to returning components or systems to service; quality control records were maintained; activities were accomplished by qualified personnel; parts and materials used were properly certified; radiological controls were implemeated; and fire prevention controls were implemente Work requests were reviewed to determine the status of outstanding jobs and to ensure that priority is assigned to safety-related equipment maintenance which may affect system performanc The NRC inspectors noted that a backlog of outstanding job orders (J0) exists for the Unit 2 process and area radiation monitoring system and for the Unit 2 fire alarm syste The following maintenance activities were observed:

. Removal of the Unit 2 emergency diesel generator rotor (Procedure 2407.44, JO 87750)

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Replacement of Unit 2 emergency diesel generator rotor (JO 86314)

. Replacement of Unit 2 emergency feedwater pump mechanical seal (JO 87707)

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Testing of Unit 2 emergency diesel generator after rotor repair (Work Plan 2409.23)

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Calibration of Unit 2 emergency diesel generator starting air compressor pressure switches (JO 83930)

. Repair of Unit 2 service water pump (JO 521326)

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Preventive maintenance en Unit 1 emergency diesel generator starting air compressor (JO 522319)

. Replacement of Unit 1 service water discharge strainer studs (JO 70523)

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Repair of Unit 1 source range signal processor (JO 88541) l

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Repair of autostart circuitry for Unit 2 engineered safeguards features pump room cooler (JO 88901)

! No violations or deviations were identified.

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. . o-8-8. Maintenance Records Review (Units 1 and 2)

This inspection was performed to verify that maintenance activities on safety-related systems and components were conducted in accordance with approved procedures and in conformance with Technical Specification requirement Records Review Corrective and/or preventive maintenance records were reviewed for the following components:

Number Component 2 TIC-4906 Boric acid tank temperature indicator and controller RE-3618 Discharge fiume radiation monitor 2XR-8347 Seismic peak recording accelerometer P39A Boric acid pump VSFM-1A Reactor building cooler fan motor CV-7444 Reactor building isolation valve for hydrogen purge system 2P36C Charging pump FI-1209 High pressure injection flow indicator 2PT-5012 Safety injection tank pressure transmitter PM39A Boric acid pump motor 2M55A Hydrogen recombiner 2CV-3200-2 Containment isolation valve for fire water system P35A Reactor building spray pump 2P89A High pressure safety injection pump 2SI-13A High pressure safety injection check valve CV-1050 Decay heat removal system isolation valve ;

006 Station battery 2031 Battery charger I

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. The NRC inspectors' review of these records indicated that:

. Administrative approvals were obtained prior to work initiatio . Limiting conditions for operation were met while the components or systems were out of servic . Approved procedures were used when require . Quality control inspections were performed and documented when require . Testing was performed, when required, prior to returning the equipment to servic . Maintenance was accomplished by qualified personne . Corrective and preventive maintenance records were retrievabl . Job orders were properly reviewed by licensee personne Maintenance history at the site is maintained on microfilm with a computer-based index syste The NRC inspectors found this system to be awkward to use, requiring considerable skill and experience on the part of the licensee personnel searching the system for the requested records. Apparently records have been indexed in an inconsistent manner, requiring several different types of searches to retrieve all applicable records. Licensee personnel informed the NRC inspectors that an improved maintenance history filing system is currently being develope B. Procedures Review The NRC inspectors reviewed a sampling of the procedures associated with the corrective and preventive maintenance activities performed on the components listed abov The procedures reviewed are listed below:

Number Title 1307.06 006 Quarterly Surveillance 1402.03 Reactor Building Spray Pump Disassembly, Inspection, and Reassembly 1403.03 Limitorque Motor Operated Valve Inspection and Setup 1403.08 Reactor Building Cooling Fan Motor Inspection / Repair and Preventive Maintenance 2304.16 Hydrogen Recombiner Inspection and Electrical Testing t

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-10-2304.56 Peak Recording Accelerometer 2304.64 Boric Acid Tank Instrumentation 2402.03 Disassembly, Inspection, and Repair of 2SI-13A 2402.36 2P89 High Pressure Safety Injection Pump Maintenance 2405.01 Station Batteries Points considered during this review included:

. Technical adequacy of the procedures

. Use of inspection and hold points

. Inclusion of testing requirements

. Conformance to licensee's administrative requirements

. Provisions for proper return to service of components

. Consideration of Technical Specification requirements

. Identification of parts and materials

. Consideration of radiological hazards

. Identification of special tools required

. Identification of test equipment required

. Verification of current calibration status for special tools and test equipment C. Job Order Tracking The NRC inspectors reviewed a listing of job orders for corrective maintenance on safety-related component This listing, from the licensee's job order tracking system, included over 2000 job orders which have been initiated but not completed. About 25 percent of the listed job orders had been cancelled. Licensee representatives researched a small sample of the open job orders and found that, in most cases, the job had been completed long ago; the job order had been reviewed and filed; but the tracking system had not been updated. Licensee representatives indicated that a new job order tracking system is scheduled to be implemented on August 1, 198 D. Conclusions No violations or deviations were identified. Documentation of reviewed maintenance activities was adequate, but the licensee's maintenance history and job order tracking systems need improvemen This is an open item pending the NRC inspector's review of the implementation of the licensee's revised systems. (313/8513-01; 368/8513-02)

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! -11-9. Requalification Training (Units 1 and 2)

The NRC inspector reviewed licensed operator requalification training to verify that it is being conducted in accordance with the licensee's l approved requalification training program and 10 CFR Part 55, Appendix A.

i The requirements for the licensee's approved requalification training program are contained in Procedure 1023.08, " Operations Training Program,"

Revision 1, dated February 12, 198 The NRC inspector reviewed the requalification training program to verify that any changes made to the program since the last NRC inspection were made in accordance with the approved program. No instances were noted where program changes were made that didn't meet the requirements of the approved progra The NRC inspector reviewed the requalification records for a sample of licensed operators. The review included the following documentation:

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. Lecture schedules

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. Annual requalification examinations and responses

. Lecture attendance sheets

. Reactivity manipulation sheets

. Annual performance evaluations

. Emergency and abnormal procedures review sheets

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. Weekly requalification quizzes and responses i The licensee issues a list of abnormal and emergency prceedures to each operator twice each year. The operator reads all procedures on the list and signs the sheets indicating that he/she has reviewed the contents of the listed procedures. During review of the sheets, the NRC inspector noted that the list used by the Unit 2 operators did not contain all the appropriate emergency and abnormal procedures. Procedures 2203.10

"Above Normal Hydrogen-Oxygen Concentration," 2203.10 " Natural Circulation Cooldown," and 2203.14. " Alternate Shutdown," were omitted from the lis Procedure 2203.10 was initially issued in 1981, and Procedures 2203.13 and 2203.14 in 1983. Section 3.d of 10 CFR Part 55, Appendix A, requires each licensed operator to review the contents of all abnormal and emergency procedures on a regularly scheduled basi Procedure 1063.08, " Operations Training Program," states that licensed operators review the abnormal and emergency operating procedures not less

than twice each year. The failure of the licensed operators to review the l contents of all emergency and abnormal procedures at least twice each year is an apparent violatio (368/8513-03)

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. ,a-12-In addition to listing emergency and abnormal procedures on the review sheets, the licensee also lists other items such as emergency plan (EP)

implementing and radiological control (RC) procedures. These EP and RC procedures are not plant specific, but apply to both units. The NRC inspector reviewed the listing of the EP and RC procedures for each unit and noted that the Unit 1 list required procedures to be reviewed that were not on the Unit 2 list, and vice vers The NRC inspector discussed the need for consistency of training for operators on both units with the licensee. The licensee agreed to perform an evaluation of the consistency of training between each unit's operators. This item will remain open pending the completion of the ifcensee's evaluatio (313/8513-02; 368/8513-04)

Nonshift licensed persnnnel are required to attend lectures during the requalification year in those areas where they demonstrate weaknesses on the annual requalification examination. The NRC inspector noted that one nonshift individual had failed to attend the required lectures during the requalification year that ended in May 1985. The licensee had identified the problem prior to this inspection and is in the process of taking correctivo action. The licensee has established a new program to ensure that nonshift licensed individuals attend lectures when required. The NRC inspector will review this program during a future inspection to ensure it is functioning properl . Exit Interview i

The NRC inspectors met with Mr. J. M. Levine (ANO General Manager) and other members of the AP&L staff at the end of this inspection. At this meeting, the inspectors summarized the scope of the inspection and the findings.

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