ML022660170
| ML022660170 | |
| Person / Time | |
|---|---|
| Site: | Callaway  |
| Issue date: | 09/20/2002 |
| From: | Brockman K NRC/RGN-IV/DRP |
| To: | Randolph G Union Electric Co |
| References | |
| IR-02-009 | |
| Download: ML022660170 (13) | |
See also: IR 05000483/2002009
Text
September 20, 2002
Garry L. Randolph, Senior Vice
President and Chief Nuclear Officer
Union Electric Company
P.O. Box 620
Fulton, Missouri 65251
SUBJECT: CALLAWAY PLANT - NRC SUPPLEMENTAL INSPECTION
REPORT 50-483/02-09
Dear Mr. Randolph:
On August 23, 2002, the NRC completed a supplemental inspection at your Callaway Plant.
The enclosed report documents the inspection findings that were discussed with Mr. W. Witt
and other members of your staff.
An Augmented Team Inspection, conducted in January-February 2002, was performed in
response to the failure of a motor-driven auxiliary feedwater pump to perform its intended safety
function. A degraded condensate storage tank floating cover resulted in foam becoming
entrained in the auxiliary feedwater system suction piping. The presence of the foam caused
an on-demand failure of an auxiliary feedwater pump, while plant operators reduced reactor
power on December 3, 2001.
The Augmented Team Inspection report, NRC Inspection Report 50-483/02-07, discussed a
finding related to the degradation of the tank seal that involved the failure, on multiple
occasions, of the licensee to identify and correct a risk significant condition adverse to quality.
The finding was assessed using the Significance Determination Process and was determined to
be White. The finding had a low to moderate safety significance under the Significance
Determination Process because it involved an increase in the core damage frequency of
between 1E-6/year and 1E-5/year.
This supplemental inspection was conducted to provide assurance that the root and
contributing causes of the White finding had been identified and fully implemented, as stated in
your letter dated May 8, 2002.
The NRC concluded that your staff had effectively identified and implemented the root and
contributing causes for the inoperability of the auxiliary feedwater pump. Based on effective
implementation of the corrective actions, it appeared that the inoperability of the pump, as a
result of foam being entrained in the suction of the pump, were adequately addressed. The
White finding will be reviewed to verify all corrective actions have been satisfactorily addressed
during the problem identification and resolution inspection currently scheduled for December
2002.
Union Electric Company -2-
In accordance with 10 CFR 2.790 of the NRCs "Rules of Practice," a copy of this letter, its
enclosure, and your response will be made available electronically for public inspection in the
NRC Public Document Room or from the Publicly Available Records (PARS) component of
NRCs document system (ADAMS). ADAMS is accessible from the NRC Web site at
http://www.nrc.gov/reading-rm/adams.html (the Public Electronic Reading Room).
Sincerely,
/RA/
Ken E. Brockman, Director
Division of Reactor Projects
Docket: 50-483
License: NPF-30
Enclosure:
NRC Inspection Report
50-483/02-09
cc w/enclosure:
Professional Nuclear Consulting, Inc.
19041 Raines Drive
Derwood, Maryland 20855
John ONeill, Esq.
Shaw, Pittman, Potts & Trowbridge
2300 N. Street, N.W.
Washington, D.C. 20037
Mark A. Reidmeyer, Regional
Regulatory Affairs Supervisor
Regulatory Affairs
AmerenUE
P.O. Box 620
Fulton, Missouri 65251
Manager - Electric Department
Missouri Public Service Commission
301 W. High
P.O. Box 360
Jefferson City, Missouri 65102
Ronald A. Kucera, Deputy Director
for Public Policy
Union Electric Company -3-
Department of Natural Resources
205 Jefferson Street
Jefferson City, Missouri 65101
Otto L. Maynard, President and
Chief Executive Officer
Wolf Creek Nuclear Operating Corporation
P.O. Box 411
Burlington, Kansas 66839
Dan I. Bolef, President
Kay Drey, Representative
Board of Directors Coalition
for the Environment
6267 Delmar Boulevard
University City, Missouri 63130
Lee Fritz, Presiding Commissioner
Callaway County Courthouse
10 East Fifth Street
Fulton, Missouri 65251
J. V. Laux, Manager
Quality Assurance
AmerenUE
P.O. Box 620
Fulton, Missouri 65251
Jerry Uhlmann, Director
State Emergency Management Agency
P.O. Box 116
Jefferson City, Missouri 65101
Gary McNutt, Director
Section for Environmental Public Health
P.O. Box 570
Jefferson City, Missouri 65102-0570
John D. Blosser, Manager
Regulatory Affairs
AmerenUE
P.O. Box 620
Fulton, Missouri 65251
Union Electric Company -4-
Electronic distribution by RIV:
Regional Administrator (EWM)
DRP Director (KEB)
DRS Director (EEC)
Senior Resident Inspector (MPS)
Branch Chief, DRP/B (DNG)
Senior Project Engineer, DRP/B (RAK1)
Staff Chief, DRP/TSS (PHH)
RITS Coordinator (NBH)
Branch Chief, DRS/PSB (GMG)
Reactor Inspector, DRS/PSB (LTR)
Scott Morris (SAM1)
CWY Site Secretary (DVY)
R:\_CW\2002\CW2002-09RP-PHH.wpd
RIV:PE/DRPD C:DRP/TSS C:DRP/B D:DRP
ELCrowe PHHarrell DNGraves KEBrockman
T - PHHarrell /RA/ RAKopriva for /RA/
9/17/02 9/17/02 9/19/02 9/20/02
OFFICIAL RECORD COPY T=Telephone E=E-mail F=Fax
ENCLOSURE
U.S. NUCLEAR REGULATORY COMMISSION
REGION IV
Docket: 50-483
License: NPF-30
Licensee: Union Electric Company
Facility: Callaway Plant
Report: 50-483/02-09
Location: Junction Highway CC and Highway O
Fulton, Missouri
Date: August 19-23, 2002
Inspectors: P. Harrell, Chief, Technical Support Staff
E. Crowe, Project Engineer, DRP
Accompanying
Personnel: C. Neill, Engineering Associate, DRP
Approved by: K. Brockman, Director, Division of Reactor Projects
SUMMARY OF FINDINGS
Callaway Plant
NRC Inspection Report 50-483/02-09
IR 05000483-02-09; on 08/12/2002-08/16/2002; Union Electric Co; Callaway Plant
Supplemental Inspection Report
This inspection was conducted by the Chief, Technical Support Staff, a Project Engineer, and
an Engineering Associate. The inspection did not identify any safety significant findings. The
NRCs program for overseeing the safe operation of commercial nuclear power reactors is
described at its Reactor Oversight Process web site at
http://www.nrc.gov/NRR/OVERSIGHT/index.html.
Report Details
01 Inspection Scope
This supplemental inspection was performed by the NRC in accordance with Inspection
Procedure 95002, Inspection for One Degraded Cornerstone or Any Three White
Inputs in a Strategic Performance Area. This inspection assessed the implementation
of the corrective actions taken by the licensee to address an on-demand failure of an
auxiliary feedwater pump (AFW) to start. A review was conducted to ensure that the
licensee had implemented the identified corrective actions in an effective manner and to
ensure that all possible contributing causes had been identified and addressed. In
addition, an independent verification was conducted of the licensees net positive
suction head (NPSH) calculations for the AFW pumps.
NRC Inspection Report 50-483/02-07 reviewed and documented many of the inspection
attributes provided in Inspection Procedure 95002. This inspection reviewed the
remaining attributes.
02 Review of the Licensees Corrective Actions (95002)
02.01 Commitments Made by Licensee to Address White Finding
In a letter dated May 8, 2002, the licensee committed to complete the following
corrective actions:
- The old floating cover was removed from the condensate storage tank (CST).
Plans were to install a new seal during the next refueling outage in the fall of
2002.
- Procedure APA-ZZ-0500, Corrective Action Program, was revised to:
(1) require operability determinations to be completed within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />; (2) require
the Manager, Callaway Plant, or his designee, to identify the root cause team
composition, scope, and due date within 2 working days of the designation of a
Significant Level 1 corrective action report (CAR); (3) require completion of
Significant Level 1 and 2 CAR evaluations within 45 days or sooner,
commensurate with significance and plant needs; and (4) embrace the Generic
Letter 91-18 philosophy.
- Performance indicators were enhanced to ensure effective monitoring of the
corrective action program.
- Followup training for the corrective action program changes was provided using
an outside consultant.
02.02 Review of Licensees Corrective Actions
a. The old floating cover was removed from the CST. Plans were to install a new seal
during the next refueling outage in the fall of 2002.
-2-
The inspectors reviewed the current status of the floating cover for the CST and
determined that the old cover had been removed. In context with this effort, the
inspectors also reviewed the calculations to independently verify that the required NPSH
was available for the AFW feedwater pumps.
The inspectors noted that the floating cover would not be replaced until the upcoming
refueling outage. Review of the replacement of the cover will be conducted during
performance of the problem identification and resolution inspection currently scheduled
for December 2002.
The inspectors reviewed the NPSH calculations for the AFW pumps. No problems were
noted that affected the overall conclusions of the calculations that determined sufficient
NPSH was available for the current configuration of the CST and the AFW systems.
b. Procedure APA-ZZ-0500, Corrective Action Program, was revised to: (1) require
operability determinations to be completed within 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />; (2) require the Manager,
Callaway Plant, or his designee, to identify the root cause team composition, scope, and
due date within 2 working days of the designation of a Significant Level 1 corrective
action report (CAR); (3) require completion of Significant Level 1 and 2 CAR evaluations
within 45 days or sooner, commensurate with significance and plant needs; and
(4) embrace the Generic Letter 91-18 philosophy.
The inspectors reviewed Procedure APA-ZZ-0500 to verify that the commitments made
by the licensee had been included in the procedure. In addition, the inspectors
performed random reviews of CARs, operability determinations, and other documents to
verify that the licensee was appropriately implementing these new commitments.
Based on these reviews and discussions with plant personnel, it appeared that the
licensee had revised Procedure APA-ZZ-0500 to include the commitments made to the
NRC. A review of a sampling of various documents indicated that the licensee was
implementing these new requirements as was directed by Procedure APA-ZZ-0500.
c. Performance indicators were enhanced to ensure effective monitoring of the corrective
action program.
The inspectors reviewed the enhancements made to the performance indicators to
verify that the changes would provide the effective monitoring of the corrective action
program. Based on this review, no issues were identified.
d. Followup training for the corrective action program changes was provided using an
outside consultant.
The inspectors verified that the followup training provided to the licensees staff
included the appropriate information and that the appropriate staff were provided the
training. During this review, no issues were identified by the inspectors.
-3-
4. OTHER ACTIVITIES
4OA3 Event Followup (71153)
(Closed) Licensee Event Report 50-483/2002-01-00 and -01: Manual Auxiliary
Feedwater Actuation and Subsequent Gas Binding of Motor-Driven Auxiliary Feedwater
Pump A
Based on the reviews conducted during this inspection, this licensee event report is
closed.
4OA6 Management Meetings
Exit Meeting Summary
The inspectors presented the inspection results to Mr. W. Witt, Plant Manager, and
other members of licensee management at the conclusion of the inspection on
August 23, 2002. The licensee acknowledged the findings presented.
The inspectors asked the licensee whether any materials examined during the
inspection should be considered proprietary. No proprietary information was identified.
ATTACHMENT
PARTIAL LIST OF PERSONS CONTACTED
Licensee
R. Affolter, Vice President, Nuclear
S. Bond, Superintendent, Nuclear Engineering Systems
M. Evans, Manager, Operational Support
G. Harris, Design Engineer, Nuclear Engineering Design Mechanical
J. Hiller, Engineer, Regional Regulatory Affairs
V. McGaffic, Superintendent, Performance Improvement
R. Myatt, Supervisor, Reliability Group
P. Myer, Design Engineer, Nuclear Engineering Design Electrical
M. Reidmeyer, Supervisor, Regional Regulatory Affairs
E. Smith, Engineer, Inservice Testing
R. Wink, System Engineer and Administrative Supervisor
NRC
V. Gaddy, Senior Resident Inspector
ITEMS OPENED, CLOSED, AND DISCUSSED
Opened During this Inspection
None
Closed During this Inspection
None
DOCUMENTS REVIEWED
PROCEDURE TITLE REVISION
ODP-ZZ-00003 Shift Relief and Turnover 09
APA-ZZ-00542 Event Review 05
APA-ZZ-00500 Corrective Action Program 32
OSP-BL-00001 RX M/U WTR ISO VLVS W/O RCS LOOPS IN 08 & 09
OPERATION/MODE 6 ALIGNMENT
-2-
CAR TITLE
200204566 ESOL#9725 Operability Determination
200202540 ESOL#9524 Operability Determination
2002002822 Operability Determination - Pipe Wall Measured
Below Manufacturers Minimum Wall Downstream of
EAV0309
200200627 Operability Determination Improvements to APA-ZZ-
00500
200200485 Evaluate the Potential Effects of Dissolved Nitrogen
on the Aux Feedwater
200200609 Bechtel Calculation M-AL-16 Rev. 0 Contains a Non-
Conservative Value for Motor Driven Aux Feed
Pump Flow Rate
200202726 During Second Dive Inspection of the CST, An
Unexpected Item Was Recovered
200200694 Effectiveness of Incident Investigations
200200926 Low Pump DP Was Measured on A MDAFW Run
200205067 Operability Determination - Pin Hole Leak in
EFV0058
200201889 Operability Determination - Control Room Halon
Bank Depressurized
200203973 Partial SAT Surveillance on OSP-AC-0007
200203882 EFHV066 Failed to Stroke During OSP-EF-V001B
200202540 Inadvertent RCS Dilution Events from BTRS
200107423 High Main Turbine Vibration, AFAS and No Flow On
A - AFW Pump
REQUEST FOR TITLE REVISION
RESOLUTION
21816 Determine Impact on M-AL-16 for N2 and Low AL
Flow
21751 Evaluate Permanent Throttling of AFW Mini Iso Vlvs A
-3-
18621 IST TDAFW Speed Reference Acceptance Range B
CALCULATION TITLE REVISION
M-AL-24 Determine the Effect of Dissolved Nitrogen on the 0, ADD 1, &
NPSHa AL Pumps ADD 2
M-AL-16 AFW Flow Model Using Pipe2000, Modeling of the 2&3
A and B MDAFP
M-AL-30 AFW Flow Model Using Pipe2000, Modeling of the 1
A MDAFW Pump Curve Based on Performance
Data
MISCELLANEOUS TITLE REVISION
SLNRC 84-0089 SNUPPS Technical Specifications Reactor Systems May 31, 1984
Branch Issues
CN Number 02-006 Final Safety Analysis Report Change Notice -
Changes to Table 10.4-12 Related to RFR 21816A.
Regarding Clarification of the Table with Respect to
Revised NPSH Available and Pump Capacity.
M-021-00061 Instruction Manual For Centrifugal Pumps 27
CST condensate storage tank
CAR Callaway action request
CFR Code of Federal Regulations
NPSH net positive suction head
NRC U.S. Nuclear Regulatory Commission
BTRS Boron Thermal Regeneration System