IR 05000324/1993003

Insp Repts 50-324/93-03 & 50-325/93-03 on 930111-15.No Violations or Deviations Noted.Major Areas Inspected: Observation of Electrical Maintenance,Review of Licensee Actions on Restart Item B7 & Prioritization of Backlog

ML20128G685
Person / Time
Site:	Brunswick
Issue date:	02/02/1993
From:	Moore R, Shymlock M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20128G679	List: IR 05000324/1993003 ML20128G675
References
50-324-93-03, 50-324-93-3, 50-325-93-03, 50-325-93-3, NUDOCS 9302160078
Download: ML20128G685 (5)

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,8c/ N't4 UN11(D STATES

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k o NUCLEAR REGULATORY COMMissl0N HEolON14

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$ y 101 MAnlETTA STHLE T, NW,

'!- ATLANTA, GEORGIA 30323

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FEB - 2 83 Report Nos.: 50-325/93 03 and 50 324/93 03 Licensee: Carolina Power and Light Company t P. O. Box 1551  :

Raleigh, NC 27602 ,

Docket Nos.: 50 325 and 50-324 License Nos.: DPR-71 and DPR-62 -

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Facility Name: Brunswick 1 and 2 Inspection Conducted: January 11-15, 1993 Inspector: If/7)er;g . //29 b/S --

R. Moore Date Signed Approved by: h IC_S ym (b Chief (s scb5n /f d J/

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Date' Signed Plant Systems Section Engineering Branch Division of Reactor Safety SUMMARY-Scope:

This routine, unannounced inspection was conducted in the areas of observation'-

of electrical maintenance, review of licensee actions on restart item B7, and review of the prioritization and scheduling of the maintenance backlog for the emergency diesel generator Results:

In the areas inspected, violations or deviations were not identifie Ongoing maintenance activities on the EDGs were appropriately controlled. Licensee actions on restart item 87, which involved EDG-3 cylinder liner inspections, were adequate for closure of this issue. -The licensee's process for prioritization and scheduling of the EDG maintenance backlog was adequat All significant maintenance work was-scheduled to be completed during this outag ' One poor maintenance practice was noted during this inspection related to the indefinite extension of " temporary repairs". A_" temporary repair"-installed -

in the EDG-1 motor operated voltage adjuster in 1988 was still installed in 199 PDR ADOCK 05000324 0 PDR c- _ _ _ .. . _

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REPORT DETAILS 4 Persons contacted Licensee Employees 1

• J. Bates, Technical' Support Engineer

• H. Berne, QC Manager S. Bostic, Maintenance Engineering Supervisor

• M. Bradley, NAD Manager

• Callis, On-site Licensing Representative J. Franke, Technical Support Supervisor -

• R. Johnson, OM&M Manager -

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• Leininger, NED Manager

• D. McCarthy, Licensing Engineer ,

NRC Personnel

• R. Prevatte, Senior Resident inspector

• D. l'elson, Resident inspector

• H. Christensen, Region 11 Projects Section Chief d

• P. Milano, NRR Project Manager

• Attended Exit Interview Electrical Maintenance (Components & Systems) Observation of Work, Work d Activities, and Review of Quality Records (IP 62705)-

This inspectica included the observation and review of maintenance y activities on the emergency diesel generators. Additionally, the '

inspector reviewed the licensee's action to-resolve! restart item B7

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related to a cylinder inspection of EDG-3, and the licensee's process for prioritization and scheduling of the EDG main _tenance backlog.- Observation of EDG Maintenance During this inspection, -EDG-4 was inoperable while' undergoing an 18 month rout ine maintenance and surveillance inspection.-

Additionally, the licensee was inspecting EDG-4 for potentially-generic problems identified on EDG-1". EDGs-1,-2,and 3 were functional and aligned for emergency operation. Maintenance on ti EDG-4 began on January 2, 199 In addition:to the 18 month:

inspection of engine and. generator. internals, the number nine <

journal / thrust bearing was inspected, the. flex coupling was:

inspected, the collision blocks' clearances were measured,- and the-auxiliary motor driven pumps' alignments were measure Non-destructive-examination of.41 cylinder liners;provided!

preliminary indications of cracking. The licensee performed destructive testing to further evaluate this condition and determined that there was no cylinder liner cracking. New l cylinders were installed for the cylinders destroyed. The licensee's decision to test all 4 cylinders liners demonstrat'ed- !

tt ?ir commitment to resolve potential hardware problems on the EDGs.- 1

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No significant' problems were identified by the licensee during this maintenance activity on EDG-4. Post maintenance break-in-runs were scheduled for the week following- this inspection; - Work

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controls were equivalent to -those of EDG-1 maintenance which were discussed in NRC Report No. 50-325,324/92-41. Work controls continued to be adequate with respect to technical support and QC involvement, supervisory oversight, and procedure guidance.- Restart Item B7: EDG-3 Cylinder Inspection Restart item B7 addressed licensee actions, recommended by the NRC, to evaluate the result of high exhaust temperatures experienced on EDG-3. Exhaust temperatures had-exceeded the vendor manual recommended values of 775 'F. In particular, the licensee was requested to perform a boroscopic inspection of the cylinder which had experienced the highest exhaust temperatur Also the vendor was to be consulted regarding the acceptability nf operation above 775 ' The inspector reviewed WR/JO 92-AJEUI which documented completion of the requested boroscopic examination on May 16, 199 The !

inspection _i'ientified no damage to the cylinder. The licensee provided documentation from the vender, Hatch and-Kirk Inc., dated-April 22, 1992, which stated that the' exhaust temperatures-experienced by the EDG did not exceed design limits and that exhaust temperatures up to 940*f were acceptable. The high temperatures experienced by EDG-3 were within this range.- The inspector concluded that the licensee had appropriately resolved :

this restart issu :_ EDG Maintenance Backlog The inspector reviewed the licensee's arocess for prioritization'

and scheduling of the' EDG maintenance )acklog. The procedure, PN-30, Integrated Recovery Methodology, revision 1, provided guidance for this process. . Generally, this procedureLprovided:a .

methodology for screening,-categorizing, and scheduling of '

maintenance wor Specifically, the process identified work to-be L accomplished prior to plant restar :

l An IBIR was generated which identified the outstanding work-for 1 each plant system. Work items in the IBIR were divided into 7 q categories based on criteria such as operability, reliability,.

availability, -regulatory requirements,. design basis restoration ~, q and material improvements. Categories-1 through 6 were scheduled l for performance prior to restart. Individual exceptions to this

!: scheduling required approval by two separate management committees i and the site vice presiden This level of review demonstrated-

management's direct involvement. in the maintenance backlog issu The inspector reviewed the IBIRs for-the EDGs and EDG support .

systems and concluded that the work had been appropriatel i

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'3 prioritized. These reports included approximately 300 work item Only: 3 schedule exceptions or deferrals had been proposed;and-these had received a rigorous management review; two were approve The inspector noted that nearly all identified work, even category:7 items, were scheduled for performance prior to restart. The licensee has maintained two shifts of maintenance

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crews with supporting technical and support staff dedicated specifically to EDG maintenance. This resource commitment arid the EDG work accomplished thus far demonstrated management commitment to eliminate the EDG maintenance backlog and upgrade the material condition of the EDG Poor Maintenance Practice - Temporary Repair Extensions During review of the EDG backlog the inspector noted an example of a poor maintenance practice related to the extension of " temporary repairs". On EDG-1, non-q list parts were installed in a q-list-component, the motor operated voltage adjuster, as a temporary repair in August, 1988. This temporary repair was still installed -

in 1993. The engineering evaluation which authorized this repair included an action item to replace these parts by September,199 ,

Extensions were approved in 1991 and 1992 which indicated that the item was being tracked. A replacement MOVA unit was received in 1991 but was not acceptable for replacement. The licensee pursued-replacement of the entire component rather than the non-q parts specifically, ,

H The engineering evaluation and accompanying safety evaluation demonstrated this particular example was not safety _significan The MOVA circuit had no active safety function during emergency EDG operations. The circuit was used in the manual- EDG mode for-

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load testing. This example was a poor maintenance-practice _in that it demonstrated a weakness in following up temporary repairs in a timely manner to return a component.to-its_ design conditio Temporary conditions generally receive less-rigorous evaluations than direct replacements or modifications'. For the length of time this repair was installed, the item should have been directed to one of the more rigorous programs or the procurement problems R related to this compon;nt should have been resolve y Exit Meeting The inspection scope and results were summarized on January 15, 1993, with those-persons indicated in paragraph 1. Proprietary information is not contained.in this report. .The inspector described the-areas-inspected and: discussed in detail the inspection results. The were not dissenting comments received from the license .i

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- .4 . --_ Acronyms :an'd Abbreviat' ions

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.EDG Emergency Diesel Generator IBIR Integrated Backlog Item Report i MOVA -Motor Oper_ated Voltage' Adjuster NAD Nuclear Assurance Department NED Nuclear Engineering Department OM&M Outage Management and Modification's QC Quality Control WR/JO Work Request / Job Order

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