ML14181A298

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Discusses 950620 Mgt Meeting Conducted in Region II Ofc to Discuss Plant Outage Issues.List of Attendees Encl
ML14181A298
Person / Time
Site: Robinson 
Issue date: 06/21/1995
From: Verrelli D
NRC Office of Inspection & Enforcement (IE Region II)
To: Hinnant C
Carolina Power & Light Co
References
NUDOCS 9507110108
Download: ML14181A298 (46)
v • d • e


Text

June 21, 1995 Carolina Power and Light Company ATTN:

Mr. C. S. Hinnant Vice President H. B. Robinson Steam Electric Plant Unit 2 3581 West Entrance Road Hartsville, SC 29550

SUBJECT:

MEETING

SUMMARY

- ROBINSON

Dear Mr. Hinnant:

This refers to the management meeting conducted in the Region II Office on June 20, 1995. The purpose of the meeting was to discuss Robinson Outage issues. A list of attendees and a copy of your slides are enclosed.

It is our opinion that the meeting was beneficial and provided a better understanding of the issues and status of the facility.

In accordance with Section 2.790 of the NRC's "Rules of Practice," Part 2, Title 10, Code of Federal Regulations, a copy of this letter and its enclosures will be placed in the NRC Public Document Room.

Should you have any questions concerning this letter, please contact us.

Sincerely, David M. errelli, Chief Reactor Projects Branch 1A Division of Reactor Projects Docket No.: 50-261 License No.: DPR-23

Enclosures:

1. List of Attendees
2. Licensee Slides cc w/encls:

Dale E. Young Plant Manager H. B. Robinson Steam Electric Plant 3581 West Entrance Road Hartsville, SC 29550 (cc w/encls cont'd - See page 2) 9507110108 950621 PDR ADOCK 05000261 P

PDR

CP&L 2

(cc w/encls cont'd)

H. W. Habermeyer, Jr.

Hartsville Memorial Library Vice President 147 W. College Avenue Nuclear Services Department Hartsville, SC 29550 Carolina Power & Light Company P. 0. Box 1551

- Mail OHS7 Raleigh, NC 27602 R. M. Krich, Manager Regulatory Affairs H. B. Robinson Steam Electric Plant 3581 West Entrance Road Hartsville, SC 29550 Max Batavia, Chief Bureau of Radiological Health Dept. of Health and Environmental Control 2600 Bull Street Columbia, SC 29201 Dayne H. Brown, Director Division of Radiation Protection N. C. Department of Environmental Commerce & Natural Resources P. 0. Box 27687 Raleigh, NC 27611-7687 R. E. Jones General Counsel - Legal Department Carolina Power and Light Co.

P. 0. Box 1551 Raleigh, NC 27602 Karen E. Long Assistant Attorney General State of North Carolina P. 0. Box 629 Raleigh, NC 27602 Robert P. Gruber Executive Director Public Staff - NCUC P. 0. Box 29520 Raleigh, NC 27626-0520 Public Service Commission State of South Carolina P. 0. Box 11649 Columbia, SC 29211 Distribution w/encl:

(See page 3)

CP&L 3

Distribution w/encl:

D. Verrelli, RH B. Mozafari, NRR G. A. Hallstrom, RH PUBLIC NRC Resident Inspector U. S. Nuclear Regulatory Commission 2112 Old Camden Road Hartsville, SC 29550 SEND TO PUBLIC DOCUMENT ROOM?

YES/

NO OFFICE RII:DRP)

SIGNATURE NAMEJI Starefosatj DATE 06/_/95 06/

/95 06/

/95 06/

/95 06/

/95 06/

/95 COPY?

YES NO YES NO YES NO YES NO YES NO YES NO OFFICIAL RECORD COPY DOCUMENT NAME:

P:\\ROBIN.MSM

LIST OF ATTENDEES Nuclear Requlatory Commission S. Ebneter, Regional Administrator, Region II (RH)

L. Reyes, Deputy Regional Administrator, RII J. Johnson, Deputy Director, Division of Reactor Projects (DRP), RII A. Gibson, Director,.Division of Reactor Safety (DRS), RH D. Verrelli, Chief, Reactor Projects Branch lA, DRP, RII W. Rankin, Chief, Radiation Protection, DRS, RII Carolina Power and Light Company W. Orser, Executive Vice President C. Hinnant, Site Vice President, Robinson Unit 2 D. Young, Plant General Manager G. Miller, Manager, Robinson Engineering.

R. Krich, Manager, Regulatory Affairs D. Alexander, Group Staff Analyst ENCLOSURE 1

H. B. Robinson Steam Electric Plant, Unit No. 2 NRC Management Meeting Refueling Outage 16 Review June 20,1995 Atlanta, GA CP&L HCIDSU 2

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA e Introduction W. S. Orser/

C. S. Hinnant

  • Outage Preparations C. S. Hinnant
  • Conduct Of Outage D. E. Young

" Focus Areas D. E. Young

- Control Of Contractor Activities

- Plant Staff Performance CP&L

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA (Cont'd)

  • Special Topics And Lessons Learned G. D. Miller

- "C" Reactor Coolant Pump Flange Boric Acid Deposition And Leakage

- "A" Residual Heat Removal (RHR) System Pump Low Flow

- "B" RHR System Pump Seal Leakage

  • Conclusions/Summary C. S. Hinnant CP&L

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA e Introduction W. S. Orser/

C. S. Hinnant te*QPutage Preparations C. S. Hinnant)

  • Conduct of Outage D. E. Young 40
  • Focus Areas D. E. Young

- Control Of Contractor Activities

- Plant Staff Performance CP&L

Refueling Outage 16 Review Outage Preparations - Strategic Plan

  • Break Old Paradigms

- Involve Entire Site Staff And Other CP&L Personnel

- Minimize Number Of Contractor Personnel

- Develop More Detailed Schedule

- Look External To CP&L And Benchmark CP&L

Outage Schedule History Outage Length In Days 200 150 100 50 0 1_

YEAR 87 88 90 92 93 95 OUTAGE DAYS 110 90 182 89 63 53 CP&L

Refueling Outage 16 Review Outage Preparations - Strategic Plan

  • Support Managers Leading Outage Coordination Teams With Line Managers Directing Craft Work
  • Perform Prudent On-Line Maintenance To Reduce Shutdown Risk And Complexity
  • Increase Communications With Site Personnel Before And During Outage e Obtain Needed Technical Specification Changes/Relief*

Requests

  • Implement Document Changes At Completion Of Modification CP&L

Refueling Outage 16 Review Outage Preparations - Approach

  • Empowered Management Team To Plan And 0

Implement Outage Schedule

  • Reorganize Outage Management Unit New Outage Manager Independent Review By Industry Peer 0

New Scheduling Program - "Prestige" CP&L

Refueling Outage 16 Review Outage Preparations - Approach

  • Conduct Assessment By Nuclear Assessment Section
  • Request INPO Outage Assist Visit
  • Benchmark Outage Schedule With Other Plants
  • Establish New Outage Contractor Contracts

- ABB Partnering (CP&L Craft On ABB Crews)

- Becon Integrated Labor Contract

  • Upgrade Simulator Prior To Control Room Upgrade CP&L

ROBINSON NUCLEAR PLANT RFO 16 OUTAGE MANAGEMENT Vice President Plant General NAD Manager Manager I

I Outage Manager QC Manager Coordinatorr WORK GROUP SPONSORS SIGNIFICANT PROJECT COORDINATORS Cgr ommunications Historian/Cleric material control Mgr grsul Regulatory Affairs Work control SS Auxiliary Bldg Coordinator Mgr RefuelingCoof J

pa ng Coorinaor ro anagemen an uppo gra.

RtC upervors Opi ShlfMgri.

Coordinator earn Genierator Coordinato IS ALARA

()

Shi SupvsCordinator rutage Irng coordinator ng neef no grs uTurbine Gen Coordinators CV Coordinator ki gupervisors Mamn Shfgrs.

Scuing Coordinator Administratlie and DaIly Operations utis Coordinator Plant Support Services or no Regulatory Affairs Plant Management Training FVSW Coordinator SHIPT SCHEDULE Project Management Incore Ste Controller Coordinator

-NAD Communications l

urne Bidg Coordinator Human Resources

Outage Preparations Critical Path Schedule April 30 May 7 May 14 May 21 May 28 June 4 June 11 June 18 2May Drain RCS -10 Inches 5 May Lfead 22 May Core Reload 8 May RCS ill & Vent 3 June Reactor Critical 11 June 100% Power 4 June Unit On Line 1 June RCS Heatup 25 May Drain Cavity May SIG Eddy Current &

RCS (1 -70 Inches May Core Off Load U

e

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA e Introduction W. S. Orser/

C. S. Hinnant

  • Outage Preparations C. S. Hinnant
  • Codc Of Ouag Youn
  • Focus Areas D. E. Young

- Control Of Contractor Activities

- Plant Staff Performance CP&L

SCHEDULE PERFORMANCE Milestone Baseline Actual

__.................._ :Schedule Schedule Unit Off-Line 28 April 23:00 28 April 21:00 Rx Head Lift Complete.

04 May 21:00 05 May 04:00 Core Off-Load Complete 08 May 09:00 08 May 07:00 Core Reload Complete 22 May 04:00 21 May 04:19 RCS Fill & Vent 28 May 04:00 30 May 15:45 RCS NOT/NOP 1 June 19:00 3 June 07:00 Reactor Critical 03 June 09:00 Sync To Grid 04 June 20:00 50% Power 07 June 06:00 100% Power 11 June 09:00 REVISED OUTAGE SCHEDULE RCP Work Complete 15 June 14:00 14 June 04:00 RCS NOT/NOP 18 June 20:00 18 June 03:50 Rx Critical 19 June 23:00 18 June 18:33 Sync To Grid 21 June 07:00

Refueling Outage 16 Review Conduct Of Outage - April 28 - June 3, 1995

  • Plant Equipment Maintenance/Upgrades Completed

-Control Room Upgrade

- Safety Injection Piping Supports

- Submerged Cable Replacement

- Major Pumps And Motors Overhauled

- Safety-Related Batteries And Inverters Replaced

-Visual Inspection And Cleaning Of Steam Generators

- Large Balance Of Plant Valves Overhauled

- Operator Work-Arounds

- "Top Ten" Equipment Problem List

- Safety Injection Accumulator Check Valve Leakage Repaired

- New Voltage Regulator Installed

- Containment Penetration Seals Replaced CP&L 10

Refueling Outage 16 Review Conduct Of Outage - April 28 - June 3, 1995 V Met Contractor Utilization Plan Goals

  • Maintained Costs Below Budget Goals o Exceeded Challenging Dose Exposure Goal Due To Emergent Work o Used New Technology To Manage Worker Radiation Exposure CP&L

1995 Contractor Utilization Plan 700 650 600 550 500 450 400 350 300 250 200 150 100 50 0

JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC BASELINE BJPROJECT HOUTAGE XKACTUAL *FORECAST

ROBINSON NUCLEAR PLANT TOTAL INCREMENTAL OUTAGE COSTS 16-Jun-95 WEEKLY SPENDING 5

..4 -

.s 3-1 2.0 0

Pre as10 os 5osn asite 0sr26 on o2 0osoe o61te seas Post Am Budget 1

Actuals + Commitments TO-DATE SPENDING 20 3 m-2.8!+/-J 15~2.

2.4ut st.

0 5-I otal. ouroI giWll

0.

0 Q.

0 6.00.

20 Pre 0S1DS O51il O5ti6 05/26 080 OWOO 081ts 06123 Post au-Budget

- Actuals + Commitments -A. Projection Cost Performance

Refueling Outage 16 Review Conduct Of Outage - April 28 - June 3, 1995 o Met Contractor Utilization Plan Goals o Maintained Costs Below Budget Goals

  • Exceeded Challenging Dose Exposure Goal Due To Emergent Work
  • Used New Technology To Manage Worker Radiation Exposure CP&L 12

RO 16 DAILY DOSE Outage Goal - < 135 Rem Outage Dose (Rem) 200 150 100 50 0 29 1 3 5 7 9 1113151719212325272931 2 4 6 8 1012141618 April - June 1995 Outage Budget Outage Actual Outage Target CP&L

Refueling Outages Rem Days 1,400 400 1,200 1,000 300 800

_8.00 200 600 400 -

100 200 1

0 000 1974 1976 1978 1979 1980 1982 1984 1986 1987 1988 1990 1992 1993 1995 ExposureE 513 612 561 398 1,035 944 1,207 416 484 554 563 298 254 185 Days B

51 42 87 100 78 175 348 50 110 106 182 89 63 53 CP&L

RO 16 CONTAMINATION EVENTS Outage Goal - < 100 Events Daily Contamination Events Total Contaminations 8

120

...*'100 6

-80 4

60

-40

-20 29 1 3 5 7 9 1113151719212325272931 2 4 6 8 1012141618 April - June 1995 Skin Clothing Total Contaminations CP&L

RO 16 RADWASTE GENERATED Outage Goal - < 300 Cubic Meters Outage (Cubic Meters) 350 300 250 200 150 100 50 29 1 3 5 7 9 1113151719212325272931 2 4 6 8 10121416 April - June 1995 Outage Budget Outage Total CP&L

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA

  • Introduction W. S. Orser/

C. S. Hinnant e Outage Preparations C. S. Hinnant

  • Conduct Of Outage D. E. Young
  • Focus Areas D., E. Young

-GCntrolOf CtractorActivities

- Plant Staff Performance CP&L 13

Refueling Outage 16 Review Focus Areas

  • Control Of Contractor Activities

- Controlled Number Of Contractors As Low As Possible

- Identified Performance Concern With One Contractor Early In The Outage

  • Held High Level Meeting With Contractor Management To Address Our Concern

- Overall Good Performance By Contractors CP&L 14

Refueling Outage 16 Review Focus Areas

  • Plant Staff Performance 0

- Environmental And Radiation Control

  • Achieved Good Worker Radiation Protection/Radwaste Reduction Practices
  • Managed Worker Dose Exposure m Performed Effective Pre-Job ALARA Planning

- Maintenance 0

  • Completed 2100 Work Tickets Without Procedure Adherence Concerns
  • No Safety-Significant Maintenance Tasks Deferred
  • Substantially Reduced Number Of Control Room Indicator Deficiencies CP&L 15

Refueling Outage 16 Review Focus Areas

  • Plant Staff Performance (Cont'd)

- Operations

" Plant Shutdown Handled Well

= Recent Operation With Reduced Reactor Coolant System (RCS)

Inventory Well Executed

= Return To Service Errors

" Incidents Occurred During Shift Manned By A Particular Crew - Selected Crew Members Removed From Shift Duties

" Shift Duty Manager/Brunswick And Harris

" Requested Corporate Performance Evaluation - V. C. Summer, Surry, ANO-2 CP&L 16

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA d

0

~Deposition And Leakage

-"A" Residual Heat Removal (RHR) System Pump Low Flow x0 "B" RHR System Pump Seal Leakage

  • Conclusions/Summary C. S. Hinnant CP&L 17

Refueling Outage 16 Review Special Topics And Lessons Learned

- Boric Acid Deposition Determined To Be Due To Leaking Thermal Barrier Pressure Tap Flange

  • Pressure Tap Flange Gasket Found Degraded Minor Seepage Noted On RCP Flange In The Vicinity Of The Component Cooling Water (CCW) Outlet Line CP&L 18

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RCP (cutaway view)

I I1

THERMAL BARRIER SEAL INJECTION Robinson Nuclear Plant LOW PRESSURE TAP Reactor Coolant Pump "C" Main Flange Stud Replacements CW INLET due to Boric Acid Corrosion RFO-16, May 1995 THERMAL BARRIER HIGH PRESSURE TAP 0

0 Replaced with new AREA OF studs, 518195 SEEPAGE 1

10 Replaced with new

  • s studs, 5/17/95

.114Removed, deemed acceptable as is and returned Acceptable as is CCW OUTLET (based on VT-3 with mirror and UT)

Note: Additional wastage found on studs 7 and 22 after pressure spray wash cleaning.

Refueling Outage 16 Review Special Topics And Lessons Learned

- Based On Evidence And Discussions With Westinghouse, Decision Made To Replace Affected Flange Studs And Re-Tension All "C" RCP Main Flange Studs

  • Discussions With Westinghouse Revealed Recent Occurrences Of Flange Leakage At Other Plants With Same Model RCP

Reached Normal Operating Temperature (NOT)/ Normal Operating Pressure (NOP)

CP&L 20

Refueling Outage 16 Review Special Topics And Lessons Learned

- At NOT/NOP Conditions, Leakage In The Same Region As The Boric Acid Deposition Was Discovered During Planned Inspection

- Disassembly Of Pump Revealed That Main Flange Gasket Was Not Completely Seated Within Gasket Groove In The Region Of The Leak CP&L 21

Refueling Outage 16 Review Special Topics And Lessons Learned

- Main Flange And Thermal Barrier Flange Gaskets Replaced

  • Employed Techniques, Tools, And Engineer From Indian Point, Unit 2
  • Replacement Accomplished In ~ 75% Of The Time And ~ 50% Less Personnel Exposure Dose Than The Last Time This Task Was Performed

- Enhanced Preventive Maintenance/Inspections Activities Identified And Being Implemented

- Experience Shared With Industry CP&L 22

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA

  • Special Topics And Lessons Learned G. D. Miller

- "C" Reactor Coolant Pump Flange Boric Acid Deposition And Leakage

[-m*AvResiduaI~a Removai (RHIR) System P'ump "B" RHR System Pump Seal Leakage

  • Conclusions/Summary C. S. Hinnant CP&L 23

Refueling Outage 16 Review Special Topics And Lessons Learned

- "A" RHR Pump Was Run For Approximately One Hour With Low Flow

- Pump Test Subsequently Run And Parameters Within Allowable Values

- Concern With Pump Performance During A Thermal Transient

- Management Concluded That Level Of Assurance Of Pump Operability Was Not High Enough - Pump Declared Inoperable CP&L 24

Refueling Outage 16 Review Special Topics And Lessons Learned

  • "A" RHR System Pump (Cont'd)

- Plant Cooled Down In Accordance With Technical Specifications Pump Dissembled

- Examination Of Pump Internals Revealed No Degradation

- Pump Was Operable

- Pump Reassembled And New Seal Installed Prior To Reduced RCS Inventory Operation CP&L 25

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA

  • Special Topics And Lessons Learned G. D. Miller

- "C" Reactor Coolant Pump Flange Boric Acid Deposition And Leakage

- "A" Residual Heat Removal (RHR) System Pump Low Flow

[ "'B" RHi Systern Pump Sea Leakage]

  • Conclusions/Summary C. S. Hinnant CP&L 26

Refueling Outage 16 Review Special Topics And Lessons Learned

  • "B" RHR System Pump

- Increased Pump Seal Leakage Identified During Outage

- Evaluation Of Pump Seal Included Leakage Measurements And Discussions With Vendor And Industry Experts

- Management Reviewed Seal Performance Evaluation And Concluded That The Level Of Assurance Was Sufficiently High That The Pump Seal Would Perform Its Functions If Called Upon At Any Time During The Next Operating Cycle CP&L 27

Refueling Outage 16 Review Special Topics And Lessons Learned

  • "B" RHR System Pump (Cont'd)

- Seal Replacement Originally Planned For Next Refueling Outage

- Decision Made To Replace Seal While Plant Is Shutdown For RCP Gasket Replacement

- Seal Replacement Performed After Alternate Decay Heat Removal Methods Were Available CP&L 28

H. B. Robinson Steam Electric Plant, Unit No. 2 Refueling Outage 16 Review AGENDA

  • Special Topics And Lessons Learned G. D. Miller

- "C" Reactor Coolant Pump Flange Boric Acid Deposition And Leakage

- "A" Residual Heat Removal (RHR) System Pump Low Flow

- "B" RHR System Pump Seal Leakage

  • Concusions/Summary C. S.

Hinnant CP&L 29

Refueling Outage 16 Review Conclusions/Summary

  • Paradigms Were Broken

- Schedule

- Ownership

- Teamwork Costs

  • Outage Work Was Well Controlled And Shutdown Safety Was Maintained
  • Outage Contractors Were Tightly Controlled e Reactor Coolant Pump And Residual Heat Removal Pump Decisions Were Prudent e The Plant Is In Excellent Material Condition And Ready For Safe Operation CP&L 30
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