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IR 05000483-02-009; on 08/12/2002-08/16/2002; Union Electric Co; Callaway Plant Supplemental Inspection Report
	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)
	v • d • e

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 0.00667 hours 3.968254e-5 weeks 9.132e-6 months ; (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 0.00667 hours 3.968254e-5 weeks 9.132e-6 months ; (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

ACRONYMS

AFW auxiliary feedwater

CST condensate storage tank

CAR Callaway action request

CFR Code of Federal Regulations

RCS reactor coolant system

NPSH net positive suction head

NRC U.S. Nuclear Regulatory Commission

BTRS Boron Thermal Regeneration System

ML022660170

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