ML16342D889

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Ack Receipt of Informing NRC of Steps Taken to Correct Violations Noted in Insp Repts 50-275/97-14 & 50-323/97-14
ML16342D889
Person / Time
Site: Diablo Canyon  Pacific Gas & Electric icon.png
Issue date: 12/04/1997
From: Gwynn T
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To: Rueger G
PACIFIC GAS & ELECTRIC CO.
References
50-275-97-14, 50-323-97-14, EA-97-369, NUDOCS 9712080185
Download: ML16342D889 (32)


See also: IR 05000275/1997014

Text

CLTEGORY 2--

REGULATORY INFORMATION DISTRIBUTION SYSTEM (RIDS)

ACCESSION NBR:9712080185

. DOC-DATE: 97/12/04

NOTARIZED: NO

DOCKET

FACIL:50-275 Diablo Canyon Nuclear Power Plant, Unit 1, Pacific

Ga

05000275

50-323 Diablo Canyon Nuclear Power Plant, Unit 2, Pacific

Ga

05000323

VTB . NAME

AUTHOR AFFILIATION

, T.P.

Region

4 (Post

820201)

RECIP.NAME

RECIPIENT AFFILIATION

RUEGER,G.M.

Pacific Gas

& Electric Co.

SUBJECT: Ack receipt of 971105 ltr informing,NRC of steps

taken to

correct violations noted in insp repts 50-275/97-14

Ec

50-323/97-14.

DISTRIBUTION CODE: IE01D

COPIES

RECEIVED:LTR-

ENCL

'

SIZE:

TITLE: General

(50 Dkt)-Insp Rept/Notice of Violation Response

NOTES:

RECIPIENT

ID CODE/NAME

PD4-2

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INTERNAL: ACRS

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RECIPIENT

ID CODE/NAME

BLOOM,S

AEOD/SPD/RAB

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NUDOCS-ABSTRACT

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NOTE TO ALL "RZDS" RECIPIENTS:

PLEASE HELP US TO REDUCE WASTE. TO HAVE YOUR NAME OR ORGANIZATION REMOVED FROM DISTRIBUTION LISTS

OR REDUCE THE NUMBER OF COPIES RECEIVED BY YOU OR YOUR ORGANIZATION, CONTACT THE DOCUMENT CONTROL

DESK

(DCD)

ON EXTENSION 415-2083

TOTAL NUMBER OF COPIES

REQUIRED: LTTR

20

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UNITEDSTATES

NUCLEAR REGULATORY COMMISSION

REGION IV

611 RYAN PLAZA DRIVE, SUITE 400

ARLINGTON,TEXAS 76011 8064

XC -4 l997

EA 97-369

Gregory M. Rueger, Senior Vice President

and General Manager

Nuclear Power Generation Bus. Unit

Pacific Gas and Electric Company

Nuclear Power Generation, B14A

77 Beale Street, Room 1451

P.O. Box 770000

San Francisco, California 94177

SUBJECT:

NRC INSPECTION REPORT 50-275/97-14; 50-323/97-14

Thank you for your letter of November 5, 1997, in response to our letter and Notice

of Violation dated October 6, 1997.

We have reviewed your reply and find it responsive to

the concerns raised in our Notice of Violation. We will review the implementation of your

corrective actions during a future inspection to determine that full compliance has been

achieved and will be maintained.

Sincerely,

Thomas P. Gwynn, Dir

tor

Division of Reactor Pr

ect

Docket Nos.:

50-275

.50-323

License Nos.:

DPR-80

DPR-82

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CC:

Dr. Richard Ferguson

Energy Chair

Sierra Club California

1100 lith Street, Suite 311

Sacramento,

California 95814

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PDR

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Pacific Gas and Electric Company

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Ms. Nancy Culver

San Luis Obispo Mothers for Peace

P.O. Box 164

Pismo Beach, California'3448

Chairman

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San Luis Obispo County Board of

Supervisors

Room 370--: .,

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County Government. Center

San Luis Obispo, California 93408

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Mr. Truman Burns>Mr. Robert Kinosian

California Public Utilities Commission

505 Van'ess,

Rm. 4'1 02

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San Francisco, California 94102

Robert R. Wellington, Esq.

Legal Counsel

Diablo Can'yon Independent Safety Committee

857 Cass Street, Suite D

Monterey, California 93940

Mr. Steve Hsu

Radiologic Health Branch

State Department of Health Services

P.O. Box 942732

Sacramento,

California 94234

Christopher J. Warner, Esq.

Pacific Gas and Electric Company

P.O. Box 7442

San Francisco, California 94120

Robert P. Powers, Vice President

and Plant Manager

Diablo Canyon Power Plant

P.O. Box 56

Avila Beach, California 93424

Managing Editor

Telegram-Tribune

1321 Johnson Avenue

P.O. Box 112

San Luis Obispo, California 93406

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Pacific Gas and Electric Company

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bcc to DCD IE01

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Regional Administrator

DRP Director

Branch Chief (DRP/E, WCFO)

Senior Project Inspector (DRP/E, WCFO)

Branch Chief (DRP/TSS)

WCFO File

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Resident Inspector

DRS-PSB

MIS System

RIV File

M. Hammond (PAO, WCFO)

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"E"-"Copy with enctosures "N"= No copy

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Pacific Gas and Electric Company

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bcc to DCD IE01

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Regional Administrator

DRP Director

Branch Chief (DRP/E, WC')

Senior Proje'ct Ins'pector (DRP/E, WC

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Pacific Gas and Bectrfc Company

November 5, 1997

245 Market Street. Room 937-N9B

San Francisco. CA 94105

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Code N9B

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P.O. Box 770000

San Francisco. CA 94177

415:973-4684 Fax 415;973-2313

Gregory M. Rueger

, Senior Vice PresideaP+g

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PG&E Letter DCL-97-184

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U.S. Nuclear Regulatory Commission

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ATTN: Document Control Desk

Washington, DC 20555

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'ocket

No. 50-275, OL-DPR-80,: -;-,.

Docket No. 50-323, OL-DPR-82

Diablo Canyon Units 1 and2

Re

I to a Notice of Violation - Ins ection Re ort Nos. 50-275/97-14 and

50-323/97-1 4

Dear Commissioners and Staff:

NRC Inspection Report (IR) Nos. 50-275/97-14 and 50-323/97-14, dated

October 6, 1997, included three Severity Level IVviolations. The three

violations are:

(1) failure to meet the requirements of 10 CFR 50.65, the

NRC's Maintenance Rule (MR), in that certain auxiliary saltwater (ASW)

system check valves were not being effectively maintained to assure they

performed their intended functions, (2) failure to consistently document

these occurrences on action requests (ARs), and (3) failure to comply

with the requirements of Technical Specification 3.0.3 when the check

valves were removed from both trains of the Unit 1 ASW system for

approximately 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> in 1991.

As PG&E stated at the September 22, 1997, Predecisional Enforcement

Conference and as noted in the NRC's'IR cover letter, the root cause for

these violations was PG&E's failure, despite several opportunities, to

recognize the relationship between the functionality of the check valves

and the operability of the ASW system.

This continuing failure to

recognize the importance of the valves contributed to the failure to

document recurring problems, which prevented the valves from being

properly evaluated under the MR. PG&E is taking actions to prevent

check valve failures by increased inspection and maintenance activities,

placement of the check valves in MR goal setting, and evaluating design

changes.

0

Document Control Desk

November 5, 1997

Page 2

To address potential generic issues in light of the findings made during

the check valve investigation, PG8 E has completed a review of

preventive maintenance records to identify any similar failures to initiate

ARs and a review of sele'cted Class II equipment to identify other

" equipment or design features which support safety systems.

Additionally,

PG8 E has'initiated reviews of: (1) licensing and design basis documents

to identify other subtle design features which may be relied upon to

support safety systems or to mitigate design basis events, and (2) ARs

initiated during the last two years to ensure that MR functional failures

have been appropriately identified and evaluated.

From the reviews that have been completed to date, PGRE believes that

problems associated with ineffective maintenance are isolated to the

ASW check valves and are not indicative of programmatic deficiencies in

the maintenance of similar equipment.

PG8 E's reply to the notice of violation is enclosed.

Sincerely,

Gregory M. Rueger

cc:

Steven D. Bloom

Ellis W. Merschoff

Kenneth E. Perkins

David L. Proulx

Diablo Distribution

INPO

Enclosure

WEC/2237/N0002034

Enclosure

PG&E Letter DCL-97-184

l

REPLY TO A N'OTICE OF VIOLATION

INSPECTION REPORT NOS. 50-275/97-14 AND 50-323/97-14

On October 6, 1997, as part of NRC Inspection Report (IR) Nos. 50-275/97-14

and 50-323/97-14, NRC Region IVissued three Severity Level IVviolations to

Diablo Canyon Power Plant, Units 1 and 2. The 'statements of violation and

PG&E's reply are documented below.

STATEMENT OF VIOLATIONA

10 CFR 50.65(a)(1) states, in part, that holders ofan operating license shall

monitor the performance or condition ofstructures, systems, and componenfs

(SSCs), as defined by 10 CFR 50.65(b), against licensee-established

goals, in a

manner sufficienf to provide reasonable assurance

that such SSCs are capable

offulfillingtheirinfended functions.

When fhe performance or condition ofa SSC

does not meef esfablished goals, appropnate corrective action shall be taken.

10 CFR 50.65(a)(2) requires, in part, that monifonng as specified in 10 CFR 50.65 Section (a)(1) is not required where it has been demonstrated that fhe

performance or condition ofan SSC is being effectivel controlled through the

performance ofappropriate preventive mainfenance, such that fhe SSC remains

capable ofperforming its intended functions.

Contrary to 10 CFR 50.65(a)(2), as ofJuly 10, 1996, the pointin time thaf fhe

licensee elecfed to nof monitor the performance or condition ofauxiliary saltwater

(ASW)system pump vaulf drain line check valves against licensee-established

goals pursuant to fhe requirements of50.65(a)(1), the licensee failed to

demonstrate that the peiformance or condition ofthe check valves was being

effectively controlled through fhe performance ofappropriate preventive

maintenance,

such that they remained capable ofperforming theirintended

function. In fact, prevenfive maintenance ofthese check valves wasineffecfive

in assuring thaf they remained capable ofperforming theirintended function.

(01014)

Thisis a Severity Level IVviolation (Supplement I).

REASON FOR THE VIOLATIONA

PG&E agrees with the violation as stated in the IR.

At the September 22, 1997, Predecisional Enforcement Conference, PG8 E

presented findings from an evaluation of the ineffective maintenance practices

for the auxiliary saltwater pump (ASWP) vault drain line check valves. Actions

were first taken to implement preventive maintenance (PM) of these particular

Enclosure

PGRE Letter DCL-97-184

f

valves in 1988. Although repeated unsatisfactory inspection findings resulted in

reduction of the interval between valve inspections from 36 to 24 months, and 24

to 12 months, these actions were ineffective in preventing recurring valve

degradation.

PGRE attributes these ineffective actions to its failure to fully

understand the role of these check valves in supporting Technical Specification

(TS) operability of the auxiliary saltwater (ASW) system.

As stated at the

Predecisional Enforcement Conference, a number of events occurred prior'o"

July 10, 1996, the date of the Maintenance Rule (MR) implementation, which

contributed to this failure. These events are summarized below:

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1.

In 1991, an engineering evaluation was performed to assess

operability

for an'event in which both, Unit 1 check valves were co'ncurrently removed

for maintenance for approximately 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />. The"evaluation erroneously

concluded that the plant was not outside the design basis with both check

valves removed:

This event is discussed further in respons'e to

Violation C.

Due to this erroneous engineering evaluation, a 1991 nonconformance

report (NCR) which questioned the appropriateness

of the 24-hour

concurrent removal of the valves, as well as the as-found valve

conditions, was closed.

However, some of the proposed corrective

actions from the NCR were not adequately implemented.

Had the

corrective actions been adequately implemented, it is unlikely that the

continued failures of these valves during maintenance inspections would

have occurred.

3.

As discussed further in Violation B, the maintenance personnel

performing the check valve inspections were provided with unclear

problem reporting guidance.

Thus, action requests (ARs), PG8E's

routine problem reporting documents, were not written to document as-

found conditions that resulted in failed inspections.

The failure to'write

ARs contributed to PG8 E's inability to identify the failed inspections as

Maintenance Rule functional failures (MRFFs) and led to omission of the

valves in 10 CFR 50.65(a)(1) goal setting.

4.

Finally, there were several instances where ARs were written for ASW

check valve PM failures, but were not properly evaluated under the MR.

This weakness

in the MR Program was associated with the limited criteria

used by reviewing personnel to determine ifevents described in the ARs

constituted MRFFs.

CORRECTIVE STEPS TAKENAND RESULTS ACHIEVED

To assure check valve operability followingthe June and July 1997 inspections,

the ASW drain lines were flushed; the ASW rooms, drains, and lines were

Enclosure

PG&E Letter DCL-97-184

= cleaned; temporary filters were installed in the floor drains to prevent debris

entry into the valves; and frequent inspections of the floor drains were

conducted.

Filter inspections are currently performed weekly.

PG&E is conducting check valve inspections on an approximate 56 day interval.

This interval may be lengthened as corrective actions are determined to be

effective.

Since these actions have been taken, nine check valve inspections have been

performed; all with satisfactory as-found valve conditions.

I ~ 'I ( ~

II

The ASW drain check valves have been placed in MR goal setting with the goal

of no additional failures during the goal-setting period.

As discussed at the Predecisional Enforcement'Conference,

PG&E has

taken'ctions

to address potential generic problems in light of the ASW check valve

findings. These actions included a review of selected Class II equipment to

identify other equipment or design features which support safety systems.

These reviews resulted in several specific findings, including some weaknesses

in the MR implementation.

However, PG&E has concluded that in general,

Class II equipment appears to be adequately maintained and the ASW check

valve issue appears to be isolated.

PG&E believes that effective implementation

of the MR willensure effective monitoring of Class II systems.

Management expectations for ASWP vault cleanliness have been established.

CORRECTIVE ACTIONS TQ BE TAKENTO PREVENT RECURRENCE

PG&E willenhance the housekeeping controls during significant

maintenance activities within the ASWP vaults. These controls should be

more appropriate for preventing debris and dirt from entering the drain

lines than the foreign material exclusion area controls that PG&E

indicated it would implement at the Predecisional Enforcement

Conference.

2.

PG&E is evaluating a design change to decrease

check valve

susceptibility to debris.

3.

PG&E is reviewing licensing and design basis documents to identify other

subtle design features which may be relied upon to support safety

systems or to mitigate design basis events.

4.

PG&E is reviewing ARs initiated since September 1995 to ensure that

MRFFs have been appropriately identified and evaluated.

Enclosure

PGKE Letter DCL-97-184

(

DATE YVHEN FULLCOMPLlANGEWtLLBE ACHIEYED

k

PGRE is in full compliance with respect to the ASW check valves.

Housekeeping controls for the ASWP vaults willbe enhanced by January 31,

1998. The design change, ifadopted willbe implemented during the Unit 2

eighth refueling outage and.the Unit 1 ninth refueling outage.

PGRE will,

complete the design feature and AR reviews by April30, 1998.

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1

Enclosure

PG8E Letter DCL-97-184

STATEMENT OF VIOLATION8

Diablo Canyon Technical Specification 6.8.1 sfafes that written procedures shall

be established, implemenfed and maintained covering fhe applicable procedures

recommendedin Appendix A ofRegulatory Guide 1.33, Revision 2, February

19?8.

Regulatory Guide 1.33> Revision 2, February 1978, Section Q.a, states in

part that maintenance that can affecf /he performance ofsafety-related

equipment should be performed in accordance

wifh wnffen procedures.

Infer-Departmental Administrative Procedure OM?-ID1, "Problem Identification

and Resolution - Action 'Requ'ests," requires that problems be documented'on'an

Action Request (AR). Affachment 7.2 to th'e'procedure, in part, defines'p'roblem

cnteria as conditions which r'ender anitem or activity unaccepfable or

'ndeterminafe

or could'negativelyimpacf systems, strucfures or componenfsif

leff uncorrected.

Confrary to the above, as ofJu'ne 25, 1997,during the performance of

maintenance activifies toinspecf ASM/pump vault drain line check valves, Acfion

Requests were nof wnffen to document problems as required by Procedure

OM?-ID1. The inspecfions revealed thaf fhe check valve was incapable of

stopping back flowforinspections performed on August 2 and 4, and September

6 and 8, 1994.

These inspection results were condifions which rendered the

valves unacceptable and negativelyimpacted the ASWsystem.

(02014)

This is a Severity Level IYviolation (Supplement I).

REASON FOR THE VIOLATION8

PG8 E agrees with the violation as stated in the IR.

As stated at the Predecisional Enforcement Conference, the original guidance in

Maintenance Procedure (MP) M-51.14, "Check Valve Inspection Program," did

not clearly communicate management expectations that ARs be written for as-

found problems with check valves.

From 1991 to 1996, the procedure required

ARs for parts, materials, or workmanship deficiencies that could not be corrected

during the course of maintenance.

Accordingly, maintenance personnel did not

always write ARs since the as-found conditions were corrected.

MP M-51.14

was revised in February 1996 to require documentation of unsatisfactory as-

found conditions and generation of ARs. Subsequent

reviews indicate that ARs

were appropriately written followingthe procedure revision.

. Enclosure

PG&E Letter DGL-97-184

CORRECTIVE STEPS TAKENAND RESULTS ACHIEVED

IVlanagement expectations for,the generation ofARs for as-found conditions

have been reemphasized

to maintenance personnel.

To address the potential generic issue',of ARs'pot'being" written for deficiencies

and degradation, PG&E performed the following reviews:

1.": "~ Selected Class II equipment (diesel fuel oil transfer pump vault check'

'valves, circulating water pump trip, and the intake demusseling valves)

work order (WO) completion remarks were reviewed dating back to the

mid-1980s.

This review identified no failures to write ARs.

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2.

To determine the acceptability of current maintenance practices, a total of

450 preventive maintenance and corrective maintenance WOs covering

the last 6 months were randomly selected and reviewed. Three minor

cases (fastener issues) were identified where ARs should have been

written. 'ARs were subsequently written.

To determine the acceptability of past maintenance practices, over 200

PM WOs were randomly selected covering the past 4 years and reviewed

to identify any instances in which a problem was discovered during the

PM and not properly reported.

Only two instances were identified where

an AR should have been written, both involving ASW discharge vacuum

breaker check valves.

However, by the time of this review, the vacuum

breaker check valves had already been placed in MR goal setting. The

vacuum breaker check valve corrective maintenance histories were further

reviewed and it was determined that previous maintenance failures had

occurred without proper documentation.

The effect of these failures was

evaluated and determined to have no impact on system operability.

Because of the vacuum breaker check valve failures, approximately 100

PM WOs covering the past 9 years were randomly selected and reviewed

using MP M-51.14. Two inspections were identified where valves

apparently failed inspection and no ARs were written. One valve was a

.

screen wash pump discharge check valve which was found with

significant internal wear and refurbished in 1993, prior to the procedure

changes

in MP M-51 ~ 14. This valve is not subject to MR criteria. The

other valve was an ASWP discharge check valve for which an AR had

previously been written documenting and evaluating check valve leakage.

Therefore, the failure to document as-found conditions had no effect for

either valve.

0

0

Enclosure

PG8 E Letter DCL-97-184

I

For the above events where ARs had not been written, PG&E determined in

each case that there were no operability concerns.

From these reviews, PG8 E

concluded that problem reporting as required by the current PM Program is

adequate to allow functional failure determination under the MR. The specific

events involving failure to write ARs for the ASW check valves were due to a

procedural weakness...

CORRECTIVE ACTiONS TO BE TAKENTO PREVENT RECURRENCE

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Administrative procedure MA1 DC51, "Preventive Maintenance Program," willbe

revised to clarify conditions requiring documentation on ARs.

DATE WHEN!PULI COINPLIANCEWILLBE ACHIEVED

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PG&E is currently in full compliance.

Administrative procedure MA1.DC51 will

be revised by December 15, 1997.

0

Enclosure

PGBE Letter DCL-97-184

STATEIIENTOF VlOLATIONC

Technical Specifications (TS) LimitingCondition for Operation 3.7.4.1 requires

that af least two auxiliary satfwater trains be operable in Modes 1-4.

The Acfion

Statement requires that with only one auxiliarysaltwater train operable to restore

at least two trains fo an operable status within 72 hours8.333333e-4 days <br />0.02 hours <br />1.190476e-4 weeks <br />2.7396e-5 months <br /> orbein at least hot

standby within the next 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> and in cold shutdown wifhin the following30

hours.

TS Section 1.21 defines "operable" as when a system is capable ofperforming

ifs specified functions.agd when all necessary attendant auxiliary equipment that

are required forthe system to perform ifs function are also capable ofperforming

their related support funcfion.

TS 3.0.3 specifies that when a limitingcondition foroperationis not met, within

one hour action shall beinrfr'afed fo place the unitin a mode in which the

specification does not apply by placingitin at least hot standby within the next 6

hours, af least hot shutdown within fhe following 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br />, and at least cold

shutdown within the subsequent

24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />.

Contrary to the above, on August 9, 1991, with the reactorin Mode 1, both Unit 1

ASWtrains were made inoperable when both floordrain check valves (SW-1-

987 and SW-1-988) were removed at the same time forabout 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />.

The

removal ofthe check valves made th'e ASWsystem susceptible to the loss of

both ASWpumps (needed forperformance ofthe ASWsystem specified

function) in the evenf offlooding ofthe intake structure.

With bofh ASWtrains

inoperable due to the floordrain check valves being removed, the licensee failed

comply with TS 3.0.3 to initiate actions within one hour to place the unitin a

mode in which the specificafion did not apply by placing the unitin at least hot

standby within the next 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br />, and at least hot shutdown within the following 6

hours.

(03014)

This is a Severity Level IVviolation (Supplement I).

REASON FOR THE VlOLATIONC

PG8 E agrees with the violation as stated in the IR.

The failure to implement TS 3.0.3 on August 9, 1991, was due to the failure of

maintenance personnel to recognize the relationship between the functionality

of the check valves and the operability ofthe ASW system.

Though

Operations questioned ASW operability in this configuration, and an AR and

NCR were initiated, the engineering evaluation of the event erroneously

concluded that the plant was not outside its design basis during the 24-hour

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Enclosure

PG8 E Letter DCL-97-184

~

concurrent removal period. Therefore, the failure to enter TS 3.0.3 was due to

reliance on the erroneous engineering evaluation.

As stated at the Predecision'al Enforcement Conference, PG8E now believes

that the TS action statement should have been entered when a check valve

was removed since the valves perform a supporting function for ASW train

operability. PG&E also agrees, as stated in the violation, that when the Unit 1

valves. were concurrently removed in 1991, TS 3.0.3 should have been

entered.

CORRECTIVE STEPS, TAKENAND RESULTS ACHIEVED

A shift order was issued by operations on August 19, 1997, requiring operators

to declare the associated ASWP inoperable and enter the TS action statement

whenever a vault'drain line check valve is removed.

A TS interpretation (TSI) was approved by the PSRC and issued on October 31,

1997, to formalize this requirement.

CORRECTIVE ACTIONS TO BE TAKENTO PREVENT RECURRENCE

PG8 E willsubmit a License Amendment Request (LAR) or a TS Bases change

to replace the TSI.

DATE WHEN FULLCOMPLIANCEWILLBE ACHIEVED

PG8 E is currently in full compliance.

An LAR or TS Bases change will be

submitted by May 1, 1998.