ML061100222

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Summary of Meeting with Union Electric Company Regarding Callaway Plant, Which Discussed Recent Plant Performance and Various Topics
ML061100222
Person / Time
Site: Callaway Ameren icon.png
Issue date: 04/18/2006
From: Clark J
Division of Reactor Safety IV
To: Naslund C
Union Electric Co
References
Download: ML061100222 (33)
v • d • e


Text

April 18, 2006 Charles D. Naslund, Senior Vice President and Chief Nuclear Officer Union Electric Company P.O. Box 620 Fulton, MO 65251

SUBJECT:

SUMMARY

OF MEETING WITH UNION ELECTRIC COMPANY REGARDING CALLAWAY PLANT

Dear Mr. Naslund:

This refers to the public meeting conducted at the NRC Region IV office on April 13, 2006, by your staff. At this meeting, Ameren UE management discussed recent plant performance and various topics, including the steam generator and turbine rotor replacement outage, component design bases self assessment, equipment reliability issues and performance indicators, Alloy-600 mitigation plans and update on Callaways containment sump modification for the 2007 spring outage.

The attendance list is enclosed with this summary (Enclosure 1). A copy of the presentation slides is also enclosed (Enclosure 2).

In accordance with 10 CFR 2.390 of the NRC's "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).

Should you have any questions concerning this matter, we will be pleased to discuss them with you.

Sincerely,

/RA/

Jeff A. Clark, P.E., Chief Engineering Branch 1 Division of Reactor Safety Docket: 50-483 License: NPF-30

Union Electric Company DISTRIBUTION w/o Enclosure 2:

Professional Nuclear Consulting, Inc.

19041 Raines Drive Derwood, MD 20855 John ONeill, Esq.

Pillsbury Winthrop Shaw Pittman LLP 2300 N. Street, N.W.

Washington, DC 20037 Mark A. Reidmeyer, Regional Regulatory Affairs Supervisor Regulatory Affairs AmerenUE P.O. Box 620 Fulton, MO 65251 Missouri Public Service Commission Governors Office Building 200 Madison Street P.O. Box 360 Jefferson City, MO 65102 H. Floyd Gilzow Deputy Director for Policy Missouri Department of Natural Resources P. O. Box 176 Jefferson City, MO 65102-0176 Rick A. Muench, President and Chief Executive Officer Wolf Creek Nuclear Operating Corporation P.O. Box 411 Burlington, KS 66839 Dan I. Bolef, President Kay Drey, Representative Board of Directors Coalition for the Environment 6267 Delmar Boulevard University City, MO 63130 Les H. Kanuckel, Manager Quality Assurance AmerenUE P.O. Box 620 Fulton, MO 65251

Union Electric Company Director, Missouri State Emergency Management Agency P.O. Box 116 Jefferson City, MO 65102-0116 Keith D. Young, Manager Regulatory Affairs AmerenUE P.O. Box 620 Fulton, MO 65251 David E. Shafer Superintendent, Licensing Regulatory Affairs AmerenUE P.O. Box 66149, MC 470 St. Louis, MO 63166-6149 Certrec Corporation 4200 South Hulen, Suite 630 Fort Worth, TX 76109 Keith G. Henke, Planner Division of Community and Public Health Office of Emergency Coordination 930 Wildwood, P.O. Box 570 Jefferson City, MO 65102

Union Electric Company Electronic distribution by RIV:

Regional Administrator (BSM1)

DRP Director (ATH)

DRS Director (DDC)

DRS Deputy Director (RJC1)

Senior Resident Inspector (MSP)

Branch Chief, DRP/B (WBJ)

Senior Project Engineer, DRP/B (RAK1)

Team Leader, DRP/TSS (RLN1)

RITS Coordinator (KEG)

SUNSI Review Completed: __Y____

ADAMS: : Yes G No Initials: __JPR____

Publicly Available G Non-Publicly Available G Sensitive
Non-Sensitive REPLACE THIS LINE WITH FINAL LOCATION AND NAME OF FILE RI:EB1 C:EB1 JReynoso/lmb JAClark

/RA/

/RA/

04/17/06 04/18/06 OFFICIAL RECORD COPY T=Telephone E=E-mail F=Fax Meeting with Union Electric Company-Callaway Plant Attendees 04/13/06 1:30-4:30 p.m.

NAME TITLE ORGANIZATION G. Apger Reactor Inspector NRC/RIV/DRP R. Caniano Deputy Director, DRS NRC/RIV/DRS J. Clark Branch Chief NRC/RIV/EB1 F. Diya Manager, Engineering Services AmerenUE T. Herrman Vice President, Nuclear Engineering AmerenUE W. Jones Branch Chief NRC/RIV/PBB R. Kopriva Senior Project Engineer NRC/RIV/PBB B. Mallet Regional Administrator NRC/RIV K. Mills Supervising Engineer, Regional Regulatory Affairs AmerenUE D. Overland Reactor Inspector NRC/RIV/EB2 C. Paulk Senior Reactor Inspector NRC/RIV/EB1 G. Replogle Senior Reactor Inspector NRC/RIV/EB1 J. Reynoso Reactor Inspector NRC/RIV/EB1 S. Rutenkroger Reactor Inspector NRC/RIV/DRS L. Smith Branch Chief NRC/RIV/EB2 K. Young Manager, Regulatory Affairs AmerenUE Callaway Engineering Presentation to NRC Region IV Arlington, TX April 13, 2006

1 Callaway Plant Callaway Engineering Presentation to NRC Region IV April 13, 2006 Arlington, TX

2 Callaway Plant Introduction Tim Herrmann

3 Callaway Plant Callaway Plant Personnel

  • Timothy Herrmann - Vice President, Engineering
  • Fadi Diya - Manager, Engineering Services
  • Keith Mills - Supervising Engineer, Regional Regulatory Affairs / Safety Analysis

4 Callaway Plant Agenda

  • Introduction / Purpose
  • Refuel 14 Engineering Successes /

Challenges

  • Component Design Bases Audit
  • Equipment Reliability
  • Alloy 600 Mitigation Plans
  • Containment Sump Modification
  • Questions / Discussion

5 Callaway Plant Daily Average Daily Average Power Refuel 14 64 days Forced Shutdown - ESW Leak Repair Forced Shutdown - MSFIS Control power supply failure Forced Downpower - A Main Feedwater Pump Speed Control Rx Trip Forced Downpower - Hot connection on terminal board in PB04 bus feeder Breaker cubicle.

Events:

  • 2 FORTS
  • CAR 200601662-Action Level 2 Entered on Secondary Chemistry

6 Callaway Plant Quality of Engineering Products

  • Improved Quality and Technical Rigor
  • Quality Review Teams:

- Modifications

- Calculations

- Request For Resolution (RFR)

  • Engineering Corrective Action Review Board (ECARB)
  • Coaching Observations

7 Callaway Plant Backlog Reduction

  • Reduced Corrective Action Program (CAP) Backlog by 50% to About 112
  • Reduced RFR Backlog by 30% to About 150
  • Performance Review Groups (PRG),

Management Review Meetings (MRM),

and ECARB in Place:

- Oversight of Quality and Backlog Reduction

  • Work Real Time By Year End

8 Callaway Plant Refuel 14 Engineering Successes and Challenges Tim Herrmann

9 Callaway Plant Refuel 14 Major Upgrades

  • Major Component Replacements

- Steam Generators

- Turbine Rotors

  • World Record 63.5 Day Refueling Outage
  • All Design Objectives Met
  • Operational Issues:

- Gland Seal Rubs During Initial Roll-up of New Turbine Rotors

10 Callaway Plant Refuel 14 Performance

  • No Lost Time and 1 OSHA Recordable Injuries
  • No Issues Resulting From Foreign Material:

No Fuel Defects No Loose Parts

  • Reviewed About 7000 Calculations
  • Issued About 1000 New Calculations

11 Callaway Plant Refuel 14 Emergent Issues

  • Engineering Resolved 78 Equipment Emergent Issues
  • Emergent Issues Included:

- New Steam Generator Level Transmitter Unqualified Diode Replacement and Re-qualification

- Condensate Storage Tank Floating Cover Seal Replacement

- Containment Sump Valve Binding OE (Valves EJHV8811 A/B)

  • Used Lessons Learned to Develop Emergent Issues Response Process

12 Callaway Plant Component Design Bases Audit Tim Herrmann

13 Callaway Plant Component Design Bases Audit

  • High Risk Components and Operator Actions Will Be Assessed
  • Scheduled June 5 to June 23, 2006
  • Audit Team Members From Engineering, Operations, Safety Analysis, and Quality Assurance
  • Consultants and Industry Peers Will Participate

14 Callaway Plant Audit Process Station PRA Information Select ~70 Risk Significant Components Select ~10 Risk Significant Operator Actions Screen for potential low margin based on design, material, and testing review Assess design, work history, operation, testing, modifications, CAP for low margin components (~20)

Assess ~6 related or Industry OE Issues - Verify Resolution Preliminary Review Detailed Review Review procedures, verify operator knowledge, conduct field walkdowns

15 Callaway Plant Design Basis Consolidation Project

  • Upper Level Design Bases Documents (ULDBD):

- 40 Plant Systems

- 7 Topical Areas

- 5 Structures

  • Electronic Format With Links
  • Scheduled to Complete in 2008
  • Some ULDBDs Will Be Ready to Support NRC Inspection

16 Callaway Plant Equipment Reliability Fadi Diya

17 Callaway Plant Mitigating Systems Performance Index (MSPI)

Proactive Response

  • 2005 Preliminary Evaluation of At-Risk Systems

- Auxiliary Feedwater (AFW)

- Emergency AC Power (EAC)

  • Entered Into Corrective Action Program and Formed Root Cause Team
  • Root Causes:

- Optimized Preventive Maintenance (PM)

Program Not Implemented

- Worker Practices

- Management of Safety System Outages

18 Callaway Plant Mitigating Systems Performance Index (MSPI)

Proactive Response

  • Primary Actions Taken/Planned:

- Revised PMs For EAC System and Turbine Driven Auxiliary Feed Pump

- Revise PMs For Remainder of MSPI Systems

- Cycle-15 Strategies For Operational and Equipment Excellence (Approximately 40% Complete)

- Improve Training on Turbine Driven Auxiliary Feedwater Pump Controls (June 2006)

- Improve Training on Emergency Diesel Generator and Controls (June 2006)

- Develop Troubleshooting Plans For Known Auxiliary Feedwater and Emergency Diesel Generator Failure Modes (June 2006)

- Restructure the System Performance Teams (Complete For MSPI Systems)

- Continue Implementation of LCO Outage Management Improvements (In Progress)

19 Callaway Plant MSPI Auxiliary Feedwater

  • Auxiliary Feedwater:

- Turbine Driven Auxiliary Feedwater Pump Trip (2/3/2004, CARS 200400798)

- ALHV0009 Overload Relay Would Not Reset During Troubleshooting (10/21/2004, CARS 200407892)

- TDAFP Failed OSP-AL-P002 Due to FCFV0313 Valve Position Voltage (11/22/2004, CARS 200408693)

20 Callaway Plant Preventive Maintenance Optimization

  • Implementation of Industry-Standard Preventive Maintenance Bases to Improve Equipment Performance
  • Revising PMs as Sequenced on Work Schedule
  • 3-Year Window

21 Callaway Plant Preventive Maintenance Optimization Implementation MOI Status (as of 4/5/06) 100%

73%75%

100%

22%

0% 0% 0%

100%

0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0% 4% 0% 0% 0% 0% 0% 0% 0% 0% 0% 0%

100%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Fans and Their Motors Switchyard Components Air Operated Valves Terry Turbine Oil Filled Transformers Relays Motor Operated Valves Breakers Emergency Diesel Generators Diesels-Large Turbine-Feed Large Motors Heat Exchangers Breakers-Low Voltage Main Generator Check Valves MSIV/FWIV Emergency Lighting Batteries Battery Chargers and Inverters Large Pumps Relays-Control Soelnoid Valves Valve Packing Turbine-Main, Valves & EHC Hydraulics Chillers and Their Motors Tanks and Vessels Cranes/Hoists Filters, Screens, Strainers, and Ion Exchangers CRDM & Rod Drive MG Sets Security Presure Safety (Relief) Valves, Vacuum Breakers...

Small Pumps and Their Motors Air Compressors and Dryers Diesels-Small Snubbers Core Work Instructions % Complete

22 Callaway Plant Alloy 600 Mitigation Plans Fadi Diya

23 Callaway Plant Recent Information

  • Refuel 14:

- Pressurizer Alloy 600 Weld Profile Data Acquisition:

  • Five Steam Space Nozzle/Safe-end Welds
  • Surge Line

- EPRI Analysis of Profile Data

  • January 2006 Less Than 90% Coverage

- Weld Overlay Evaluation

  • January 2006

24 Callaway Plant Refuel 15 Work Scope

  • Mitigation/Inspection:

- Steam Space: Weld Overlay and Inspection

- Surge Line: Weld Overlay and Inspection

  • Vendor Selection in Progress
  • Scope Supports Outage Schedule Duration

25 Callaway Plant Containment Sump Modification Fadi Diya

26 Callaway Plant Containment Recirculation Sump Modification Sump Strainers Increasing From 800 to 6400 Sq Ft Total Area Sump Float Type Level Instrumentation Being Changed to Differential Pressure Instrumentation Tri-Sodium Phosphate (TSP) Baskets Will Be Moved From Within Current Sump Enclosure and Redesigned Debris Barriers (Doors) Will Be Installed on A and D Loops Industry and Site Testing On-going Partnering with Wolf Creek Nuclear Operating Company Implementation in Refuel 15

27 Callaway Plant Questions and Discussion

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