IR 05000483/1989018
| ML19324B775 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 10/31/1989 |
| From: | Defayette R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19324B772 | List: |
| References | |
| 50-483-89-18, NUDOCS 8911080197 | |
| Download: ML19324B775 (8) | |
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k U. S. NUCLEAR REGULATORY COMMISSION REGION !!!
Report No. 50-483/89018(DRP)
Docket No. 50-483 License No. NPF-30 Licensee: Union Electric Company i
Post Office Box 149 - Mail Code 400 f
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St. Louis, MO 63166 l
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Pacility Name: Callaway Plant, Ur.it 1 Inspection 4t Callaway Site, Steedman, MO j
Inspection Conducted:
September 1, through October 15, 1989
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Inspectors:
B. H. Little f
C. H. Brown j
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Approved By:
R.
e ayette C ief,
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Reactor Projects Section 3A Datt j
I Inspection Summary
_in_spection from September 1. through October 15. 1989 i
(Report No. 50-483/89018(DRP))
J Areas Inspected: A routine unannounced safety inspection of licensee i
self-assessment capability, plant operations, and maintenance and surveillance
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was conducted.
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Results: No violations or deviations were identified. Uti'ity management i
was actively involved in self-identification, assessment activities and was I
supportive of improvement initiatives. The independent safety engineering l
group (ISEG) provided comprehensive, technical assessment of reactive and
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proactive improvement programs (paragraph 2). Control room supervisors and
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operatorsdemonstratedimprovedcommunicationdiscipline(paragraph 3.a).
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conservative safety attitude was demonstrated by the operating crew in
response to a water lever channel failure associated with the refueling water
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storage tank (paragraph 3 b). The observed control room annunciator " black
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board" status is indicative of effective maintenance (paragraph 4).
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DETAILS f
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Persons Contacted D. f. Schnell, Senior Vice President, Nuclear
- G. L. Randolph, General Manager, Nuclear Operations
- J. D. Blosser, Manager, Callaway Plant
- C. D. Naslund, Manager. Operations Support l
'J. V. Laux, Manager, Quality Assurance
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J. R. Peevy, Assistant Manager, Technical Services i
W. -R. Campbell, Manager, Nuclear Engineering
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M. E. Taylor, Assistant Manager, Work Centrol D. E. Young, Superintendent Operations
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- W, R. Robinson, Assistant Manager, Operations and Maintenance R. R. Roselius, Superintendent, Health Physics 1. P. Sharkey, Supervising Engineer, Site Licensing
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6. J. Czeschin Superintendent, Planning and Scheduling W. H. Sheppard, Superintendent, Maintenance G. R. Pendegraff, Superintendent, Security L. H. Kanuc tel, Supervisor, Quality Assurance Program t
- G. A. Hughes, Supervisor, independent Safety Engineer Group J. C. Gearhart, Superintendent, Operations Support, Quality Assurance i
- C. S. Petzel, Quality Assurance Engineer
- H. A. Stiller, Manager Nuclear Safety and Emergency Preparedness
'M. S. Evans, Superintendent, Training
' Denotes those present at one or more exit interviews.
In addition, a number of equipment operators, reactor operators, senior reactor operators, and other members of the quality control, operations,
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maintenance, health physics, and engineering staffs were contacted.
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Licensee Self-Assessment Capability (40500)
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An inspection of the licensee's self-assessment programs was performed to evaluate the overall effectiveness of programs relating to the
identification, prevention, and correction of plant problems and
deficiencies. The inspection focused on the licensee's proactive initiatives as well as its root cause assessment of problems and i
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events. The inspection included a review of selected on-site and
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off-site committee meeting minutes, independent safety review reports
and third party assessments. The inspectors attended both routine and special on-site review coranittee meetings, and observed various licensee event reduction team 6ctivities.
Inspection findings The licensee's on-site and off-site reviev committee activities were performed in accordance with Technical Specifications (T/S) 6.5.1 and 6.5.2.
Both On-site Review Committee (ORC) and the Nuclear Safety Review i
Board (NSRB) conunittee member composition and meeting frequency have exceeded the minimum specified in the T/S.
Conrnittee members display an
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independent attitude, providing a critical challenging review of agenda
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items. Meeting minutes are maintained.
Issues not resolved during the meetings are given assignment and resolution commitment and are tracked
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in the minutes.
l The Independent Safety Engineering Group (ISEG) is very active in both
licensee initiated and industry improvement programs.
!$EG reports to the General Manager, Nuclear Operations, through the Menager, Nuclear
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Safety and Emergency Preparedness.
ISE6 has direct reporting authority i
to the Senior Vice president, Nuclear for matters involving safety.
ISEG is comprised of a supervising engineer and a staff of twelve engineers.
On a rotating basis, approximately half of ISEG's staff members are assigned to operating crews as shif t technical advisors (STAS).
This i
rotational aspect appears to enhance ISEG's assessment capability through
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knowledge of current problems and trends and operating crews' acceptance of ISEG involvement,
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ISEG is highly involved in both reactive and proactive improvement programs associated with human performance errors, and uses the Human
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Performance Evaluation System (HPES) technique in this effort.
HPES has been applied during the assessment of p16nt problems and also in the evaluation of control room and outage performance.
ISEG recommendations have led to improved work processes in the control room, including the assignment of shift outage managers in the control room during plant outage periods.
ISEG is actively involved in Callaway's event reduction program.
The
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licensee activates an event review team following reactor trips, licensee event report (LER) eventr, and incidents having safety significance.
ISEG members participate as members on these teams.
They provide an independent assessment of event causal factors and root cause.
Events
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and incidents reported by the industry are evaluated by ISEG.
Problems l
which have specific relevance to Callaway are highlighted in the
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utility's weekly newsletter and ISEG's cperating experience journal.
Significant problems, both self and industry identified, are included in
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the licensee's qualification and requalification training programs.
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In addition to routine surveillance of plant operations, ISEG performed special evaluations in a number of specific areas.
Examples of these include:
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Health physics Technical Review
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Refuel III Design Change Review
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Human performance Errors
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Motor Operated Yalve Failures
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Check Valve Maintenance program
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ISEG reports provide an independent, comprehensive technical assessment containing observations, data trends, analysis, and recommendations.
The change analysis and event and causal factor techniques are applied to performance problems to determine root cause.
Department heads appear
receptive and responsive to ISEG findings and recommendations.
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Department response provides justification in those instances where reconnendations are not adopted.
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i The inspectors found that utility managernent was actively involved in self-identification and self assessment efforts, and was supportive of i
irrprovement initiatives.
The licensee has focused attention on reducing
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t performance errors which have been the major contributcr to reportable incidents at Callaway.
It appears such efforts have had a positive effect on overall plant performance as indicated by the continuing decrease in the freque.1cy of reportable events and the significant
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reduction in plant trips.
l Ac'ivities were conducted in a safe and adequate manner.
3.
plantOperations(71707)
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Operational Scfety Verificatien
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Inspections were routinely performed to ensure that the licensee conducts activities at the facility safely and in conformance with regulatory requirements.
The inspections focused on the implernenta-
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tion and overall effectiveness of the licensee's control of operat-ing activities, and on the performance of licensed and non-licensed
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operators and shift technical advisors.
The inspections included direct observation of activities, tours of the facility, interviews
and discussions with licensee personnel, independent verification of
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safety system status and limiting conditions of operation (LCO), and
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reviews of facility procedures, records, and reports. The following items were considered during these inspections:
Adequacy of plant staffing and supervision.
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Control room professionalism, including procedure adherence,
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i operator attentiveness, and response to alarms, events, and l
off-normal conditions.
Operability of selected safety-related systems, including
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attendant alarms, instrumentation, and controls,
Maintenance of quality records and reports.
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The inspectors observed that safety system and balance of plant system status' were appropriately logged and discussed during shift turnovers.
Systems and components covered by plant technical specifications (T/S) which were removed from service for l
maintenance, were closely monitored and tracked and were restored to service within the allowable time.
The inspectors have noted an improved crew communication discipline i
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within the control room (CR) in both face to face and phone conimunications.
The licensee recently implemented CR teamwork
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developinent training which focuses on communication discipline, it i
appears the training has increased supervisor and operator sensitivity to the importance of effective communication in reducing
performance errors.
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b.
Off-shift Inspection of Control Room
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The inspectors performed routine inspections of the control room during off-shift and weekend periods; these included inspections i
between the hours of 10:00 p.m. and 5:00 a.m.
The inspections were conducted to assess overall crew performance and, specifically, control room operator attentiveness during night shifts.
The inspectors observed that control room supervisors shift
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technicaladvisors,andoperatorswereattentivetoplant i
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conditions, performed frequent panel walkdowns and were responsive to of f-normal alarms and conditions.
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On Sundey, October 15, 1989, while performing a control room observation, the inspector observed the shift crew's response to a
Iow-low level alarm on the refueling water storage tank (RWST). The
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i crew determined that one of four level channels had failed low, and
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in accordance with the T/S the inoperable channel was placed n
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bypass.
Instrumentandcontrol(I&C) technicians,throughtrouble i
shooting under a generic work request (WR) determined that the channel failure was due to the failure of circuit card BNLQY-0933.
The shift supervisor directed the call out of support personnel.
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The work was planned and performed under WR #127392.
The card was replaced and tested satisfactorily, and the channel was returned to service.
The overall effort took approxinately five hours. Although T/S
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permits continued operation with one channel inoperable and aypassed,(T/S 3.0.3).the failure of another channel would have required a yt.
shutdown The crew's response in this matter
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demonstrated a safety versus compliance attitude, c.
Plant Material Conditions / Housekeeping
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The inspectors performed routine plant tours to assess material conditions within the plant, ongoing quality activities and
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plantwide housekeeping.
The inspectors also accompanied the i
licensee's management on monthly plant tours,
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d.
Radiological Controls l
The licensee's radiological controls and practices were routinely observed by the inspectors during plant tours and during the
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inspection of selected work activities. The inspection included direct observations of health physics (HP) activities relating to
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radiological surveys and monitoring, maintenance of radiological
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control signs and barriers, contamination, and radioactive waste controls.
The inspection also included a routine review of the licensee's radiological and water chemistry control records and reports.
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Good radiological controls, conditions and practices were observed.
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Securit,y The licensee's security activities were observed by the inspectors
during routine facility tours and during the inspectors' site t
arrivals and departures. Observations included the security
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personnel's performance associated with access control, security
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checks, and surveillance activities, and focused on the adequacy of i
security staffing, the security respense (compensatory measures),
and the security staff's attentiveness and thoroughness.
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The inspector participated in the NRC's Regulatory Effectiveness
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Review (RER) conducted at the Callaway plant from September 18
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tnrough September 21, 1989. The inspector's findings were discussed with RER team members during the review. The RER results and conclusions have been conveyed to the licensee in a separate report.
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An inspection of emergency p eparedness activities was performed to assess the licensee's implementation of the emergency plan
and implementing procedures.
The inspection included monthly
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observation of emergency facilities and equipment, interviews with
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licensee staff, and a review of selected emergency implementing
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procedures.
The Callaway Plant's 'innual emergency areparedness exercise was held
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on October 11, 1989.
The inspectors caserved the control room (simulator) crew's performance throughout the exeraise and portions oftheTechnicalSupportCenter(TSC) activities. The inspectors'
specific observations and assessment of the licensee's exercise
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p(DRSS).erformance is included in NRC inspection report number 483/89013 i
i All activities were conducted in an adequate ano safe manner.
4 Maintenance / Surveillance (62703)(61726)
Selected portions of the plant surveillance, test and maintenance activities on safety-related systems and components were observed or
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i teviewed to ascertain that the activities were performed in accordance
w!th approved procedures, regulatory guides, industry codes and
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standards, and the Technical Specifications.
The following items were l
considered during these inspections:
the limiting conditions for operation were met while components or systems were removed from cervice; approvals were obtained prior to initiating the work; activities were
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accomplished using approved procedures and were inspected as applicable; functional testing and/or calibration was performed prior to returning
the components or systems to service; parts and materials that were used l
were properly certified; and appropriate fire prevention, radiological, i
and housekeeping conditions were maintained.
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The observed ongoing maintenance and surveillance activities were found
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to be properly authorized and were being performed using approved
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f-procedures.
The activities were noted to be scheduled and required
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isolations and tagging were found to be correctly carried out.
The
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limiting conditions for operation were adhered to during the performance l
of these activities.
In general, the workmanship was found to be satisf actory.
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a.
Maintenance
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f The reviewed maintenance activities included:
Work Request No.
Activity
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W124405 Repair and test GE 480 volt breaker number PG1316.
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W127392 Replace arid test RWST circuit card nutber l
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BNLQY-0933.
W128651 Repair path director for incore detector.
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W119359 Addition of " live load" washers to steam
generator blowdown heat exchanger head bolts (RFR89-5358).
The licensee continues to aggressively pursue control room I
annunciator deficiencies.
On several occasions, an annunciator
" black board" (free of alarming annunciators) condition was l
observed.
Routinely, alarming annunciators number less than six and i
are the result of on-going surveillance activities.
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Surveillance
The reviewed surveillances included:
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Procedure No.
Activity ISF-AB-0P546 Functional test of steam generator (S/G)
I ISF-AB-0PS24 pressure transmitters.
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ISF-AB-0P534 i
ISF-AL-00P38 Functional test of the auxiliary feedwater
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pump suction pressure transmitter.
l MSE-PA-QYO11 Reactor coolant pump 'B' underfrequency functional test.
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ITP-NF-00001 Load shedding end emergency load sequencing
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relay driver functional test.
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ISP-SB-0001A Reactor trip breaker trip actuating device g
operational test.
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All activities were conducted in an adequate and safe manntr.
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5.
ExitMeeting__(30703)
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The inspectors met with licensee representatives (denoted under Persons
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Contacted) at intervals during the ins pection period. The inspectors i
L summarized tLa scope and findings of tie inspection. The licensee
l representatives acknowledged the findings as reported herein.
The
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inspectors also discussed the likely informational content of the
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i inspection report with regard to docunents or processes reviewed by the i
inspectors during the inspection.
The licensee did not identify any such
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documents / processes as proprietary.
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