ML17317B453

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IE Insp Rept 50-315/79-13 & 50-316/79-10 on 790505-31. Noncompliance Noted:Failure to Maintain or Implement Procedures & Mod Not Revealed or Approved by Onsite Review Committee
ML17317B453
Person / Time
Site: Cook  American Electric Power icon.png
Issue date: 06/21/1979
From: Baker K, Boyd D, Masse R
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML17317B450 List:
References
50-315-79-13, 50-316-79-10, NUDOCS 7908150382
Download: ML17317B453 (18)


See also: IR 05000315/1979013

Text

U.S.

NUCLEAR REGULATORY COMMISSION

OFFICE

OF INSPECTION AND ENFORCEMENT

REGION III

Report No. 50-315/79-13;

50-316/79-10

Docket No. 50-315;

50-316

License

No. DPR-58;

DPR-74

Licensee:

American Electric Power Service

Corporation

Indiana

and Michigan Power

Company

2 Broadway

New York, NY

10004

Facility Name:

Donald C.

Cook Nuclear Power Plant, Units

1 and

2

A

Inspection At:

Donald C.

Cook Site,

Bridgman, Michigan

Inspection Conducted:

Ma

5-31,

1979

Inspectors:

. E.

Masse

g~r

y

K.

. Baker

Approved By:

D.

. Boyd, Acting Chief

Reactor Projects

Section

3

4'~ 7P

l'g~ q

Ins ection

Summar

Ins ection on Ma

5-31

1979

(Re ort No. 50-315/79-13

50-316/79-10)

Safety Features;

assessment

of operating procedures;

review of feedwater

pipe cracking

on Unit

1 and Unit 2; and review of Unit

1 source

rod

location problem.

The inspection involved 230 inspection-hours

by two

NRC inspectors.

Results:

Of the five areas

inspected,

four items of noncompliance

were

noted in two of the areas

(Infraction:

failure to maintain or implement

procedures.

Paragraphs

3.a, 3.d,

and 3.j; and Infraction:

modification

not reviewed or approved

by Onsite Review Committe, Paragraph 3.b).

DETAILS

1.

Persons

Contacted

+D. Shaller, Plant Manager

  • B. Svensson,

Assistant Plant Manager

-R. Lease,

Operations

Superintendent

-R. Dudding, Maintenance

Superintendent

+J. Stietzel,

QA Supervisor

-C. Murphy, Production Supervisor, Unit 2

+H. Chadwell, Production Supervisor,

Unit

1

I,. Smith, Shift Operating Engineer

The inspectors

also contacted

a number of operators,

technicians

and

maintenance

personnel

during the course of the inspection.

-Denotes

those present at one or more of the exit

interviews'.

Review of 0 erator Trainin

On April 18,

1979,

an IE and

NRR task group of Messrs.

Streeter

and

Campbell conducted training sessions

for operators

and staff members

responsible for plant operations.

These

sessions

were relative to

the Three Mile Island Nuclear Plant "incident including event chronology,

operator actions,

resultant technical information,

and requirements

being imposed

on licensees

brought about by this incident.

In

addition to these training sessions,

the inspector also discussed

with operators

the following topics (relative to TMI information) to

ascertain

whether knowledge in these

areas

was adequate:

a.

Procedure

changes

brought about by the licensee's

response

to

IE Bulletins 79-06,79-06A,

and 79-06A (Rev. 1).

These bulletins

direct the licensee

to respond to various questions

and require-

ments pending from information received

from the TMI incident.

b.

Operator

knowledge of specific measures

which provide assurance

that Engineered

Safety Features

(ESF) would be available if

required

and, in particular,

measures

for returning such systems

to operable

status

following maintenance

and testing.

c ~

Operator

knowledge of specific and detailed

measures

to assure

that automatic actuations

of ESF are not overridden except

as

directed.

d.

Operator

knowledge of resulting conditions following reset of

ESF for systems affecting control of radioactive

gases

and

liquids.

e.

Operator

and supervisory personnel

knowledge of the provisions

and directives for early notification of serious

events.

Relative to the types of communication

now required,

several

dedicated

phones

were installed

(May 31,

1979) to assist in

open communications

between the plant and

NRC Incident Response

Centers

located in Glen Ellyn, Illinois, (Region III Office)

and Bethesda,

Maryland,

(NRC Headquarters).

Plant phones

are

installed in the following locations:

1.

2.

3.

4.

Unit 1 Control Room

Unit 2 Control Room

Shift Operating Engineer's Office

NRC Resident Inspector's Trailer

No items of noncompliance

or deviations

were identified.

3.

Ins ection of En ineered Safet

Features

(ESF)

The inspectors verified by independent

examinations of records,

procedures

and equipment that

ESF were operable in accordance

with

Technical Specifications

and that procedures

and administrative

controls provided assurance

of continued operability.

The following

paragraphs

relate to those

areas

checked:

a.

The inspectors

reviewed valve lineups, breaker lineups,

and

switch lineups for all ESF systems

and

compared

them with plant

flow diagrams to verify the adequacy of current alignment

procedures.

Numerous inconsistencies

between drawings, proce-

dures,

and as-built status

were identified, concentrated

almost

entirely in the Safety Injection, Residual Heat Removal,

and

Diesel-Generator systems'll

errors

have been

documented

and

passed

along to the licensee for appropriate action.

The inspectors,

using licensee

approved procedures,

physically

verified alignments for ESF components in accessible

areas.

Major 'components

and essential

flow paths

were verified and

a

sampling of minor valves (vents, drains, etc.)

was conducted.

For instances

of operating

components,

observation of operation

was substituted for verification of individual valve positions.

While verifying alignment of Unit 2 diesel-generators

on May 14,

1979, the inspectors

noted that the "after cooler drain valves"

had been

removed from both the

2AB and

2CD diesel generators.

These valves

appear

on flow diagram 12-5150A-14 (J-8).

The

flow diagram indicates that the valves

should be'hut.

Checkoff

sheet 5.1 of procedure

1-OHP 4021.032.006

(Rev. 2) "Emergency

Diesel Generator

Miscellaneous

System Lineup" also requires

the

valves to be shut.

Temporary

Change

No.

1, which had expired

on September

27,

1978, required the valves to be open.

The

inspectors

found that these valves

had been physically removed,

and discussions

with the licensee

indicated that the valves

had

been

removed for an extended period of time due to problems

maintaining them in the open position.

A facility change for

their removal had not been initiated, nor had the

PNSRC reviewed

.

or approved their removal.

These findings represent

apparent

noncompliance with Technical Specification 6.5.1.6.d which

requires

the

PNSRC to review proposed

changes

to equipment

affecting nuclear safety,

and of 10 CFR 50.59 requirements

to

conduct

a safety analysis prior to modification of safety

related

equipment.

The inspector

reviewed administrative controls of the licensee

to assure

that ESF components

or systems

are properly returned

to service following testing or maintenance activities.

The

controls were observed

to be adequate if properly implemented.

The inspector

reviewed

changes

that had been

made to the following

procedures

since the last surveillance tests

had been performed

to verify that,

when testing or maintenance

has

been completed,

the system will be returned to an operable

condition:

1-OHP 4030 STP.002;

1-OHP 4030 STP.004)

1-OHP 4030 STP.005;

1-OHP 4030 STP.007;

1-OHP 4030 STP.008;

1-OHP 4030 STP.009;

1-OHP 4030 STP.010;

1-OHP 4030 STP.Oll;

1"OHP 4030 STP.013)

1-OHP 4030 STP.017;

1"OHP 4030 STP.020;

1-'OHP 4030 STP.022)

1-OHP 4030 STP,024;

1-OHP 4030 STP.025;

1-OHP 4030 STP.026)

1-OHP 4030 STP.027)

1"OHP 4030 STP.033)

1-MHP 4030 STP.005)

1-MHP 4030 STP.006;

1-MHP 4030 STP.008)

1-MHP 4030 STP.009;

1"MHP 4030 STP.010)

1-MHP 4030 STP.011;

1"MHP 4030 STP.012;

1"MHP 4030 STP.013)

1"MHP 4030 STP.014)

2-OHP 4030 STP.002

2"OHP 4030 STP.004

2-OHP 4030 STP.005

2-OHP 4030 STP.007

2-OHP 4030 STP.008

2-OHP 4030 STP.009

2-OHP 4030 STP.010

2-OHP 4030 STP.011

2-OHP 4030 STP.013

2-OHP 4030 STP.017

2-OHP 4030 STP.020

2-OHP 4030 STP.022

2-OHP 4030 STP.024

2-OHP 4030 STP.025

2-OHP 4030 STP.026

2-OHP 4030 STP.027

2-OHP 4030 STP.033

2-MHP 4030 STP.005

2-MHP 4030 STP.006

2-MHP 4030 STP.008

2-MHP 4030 STP.009

2-MHP 4030 STP.010

2-MHP 4030 STP.011

2-MHP 4030 STP.012

2-MHP 4030 STP.013

2-MHP 4030 STP.014

1-THP 4030 STP.Oll;

1-THP 4030 STP.021

1-THP 4030 STP.012;

1-THP 4030 STP.022

1-THP 4030 STP.014;

1-THP 4030 STP.045

1-THP 4030 STP.015;

1-THP 4030 STP.046

1-THP 4030 STP.016;

1-THP 4030 STP.047

1-THP 4030 STP.017;

1-THP 4030 STP.048

1-THP 4030 STP.018;

1-THP 4030 STP.049

1-THP 4030 STP.019;

1-THP 4030 STP.050

1-THP 4030 STP.020;

1-THP 4030 STP.051

1-THP 4030 STP.1007

1-THP 4030 STP.214

1-THP 4030 STP.205)

1-THP 4030 STP.217

2-THP 4030 STP.100)

2-THP 4030 STP.111;

2-THP 4030 STP.112;

2-THP 4030 STP.113;

2-THP 4030 STP.114;

2-THP 4030 STP.119;

2-THP 4030 STP.120)

2-THP 4030 STP.150;

2-THP 4030 STP.205

2-THP 4030 STP.121

2-THP 4030 STP.122

2"THP 4030 STP.145

2"THP 4030 STP.146

2-THP 4030 STP.147

2"THP 4030 STP.148

2-THP 4030 STP.149

2-THP 4030 STP.151

12-THP 4030 STP.203)

12-THP 4030 STP.210

12-THP 4030 STP.204;

12-THP 4030 STP.211

12-THP 4030 STP.207;

12-THP 4030 STP.212

12-THP 4030 STP.208;

12"THP 4030 STP.216

12-THP 4030 STP.209)

12-THP 4030 STP.218

The above current,

approved procedures

include

a return to

operable

status with the following exceptions:

12-THP 4030

1-THP 4030

12-THP 4030

1-THP 4030

1-OHP 4030

2-OHP 4030

1-OHP 4030

2-OHP 4030

STP.203;

STP.205;

STP.207;

STP.214;

STP.002;

STP.002;

STP.004;

STP.004;

12-THP 4030 STP.218

1-OHP 4030 STP.008

2-OHP 4030 STP.008

1"OHP 4030 STP.010

2-OHP 4030 STP.010

1-OHP 4030 STP.005

2-OHP 4030 STP.005

1-OHP 4030 STP.007

2-OHP 4030 STP.007

The inspector also reviewed the following Instrument Maintenance

procedures

for both units:

THP 6030 IMP.014;

THP 6030 IMP.211

THP 6030 IMP.031;

THP 6030 IMP.215

THP 6030 IMP.219;

THP 6030 IMP.226

Exceptions

were noted for:

THP 6030 IMP.211;

THP 6030 IMP.215

THP 6030 IMP.226

Comments

on these procedures

have been

documented

and passed

along to the licensee for appropriate action.

On May 9,

1979, while checking temporary

changes

to procedures,

the inspector noted that procedure

2-OHP 4030 STP.005

"ECCS

Pumps Operability Test" in the Unit 2 Control Room contained

change

No'.

7 dated February 5,

1979.

The temporary

change

was

a carbon

copy with only the first level of review signed off.

A review of plant records

revealed that the temporary

change

had not been

reviewed by the

PNSRC and approved

by the Plant

Manager

as of May 9,

1979.

This finding represents

apparent

noncompliance with Technical Specification 6.8.3.c requiring

review of temporary

changes

to procedures.

The inspector

reviewed the last completed surveillance tests

on

each

ESF system

and verified that acceptance

criteria were met.

The inspector visually observed that pressurizer

level bistables

on Unit 2 had been placed in the trip position as requested

by

NRC and that surveillance

procedures reflect the change.

Unit 1 was shutdown for refueling on April 6,

1979,

and prior

to startup the licensee

intends to implement an

RFC (modification)

which will alleviate the requirement of placing level bistables

in trip.

The change

would allow a two out of three logic on

pressurizer

pressure

channels

only (not coincident with level)

for safeguards

actuation.

This modification will also take

place

on Unit 2 when approved.

The inspector

reviewed administrative controls for returning

ESF systems

to operability following extended

outages.

Plant

operating procedure

1(2)-OHP 4021.001.001

"Plant Heatup From

Cold Shutdown"

and 1(2)-OHP 4021.001.002

"Plant Startup

From

Hot. Standby to Minimum Load" contain administrative

requirements

to return

ESF systems

to operable status.

Additional controls

are provided by the Surveillance Test Program

(PMI-4030 and

implementing procedures),

the Clearance

Permit System

(PMI-2110),

and Job Order Controls

(PMI-2290).

Adherence to these

adminis-

trative controls would appear to be adequate

to assure

ESF

systems

are returned to an operable status

following outages.

The inspector

determined that the licensee

does not use independent

verification of valve/breaker/switch

alignments following

outages

and after test or maintenance activities.

The licensee

does

use independent verification for tagging out safety related

equipment to prevent the inadvertent

removal of redundant

equipment

from service.

Independent verification is also used

for radioactive effluent releases

and for jumper/bypass

installation

and removal.

The inspector verified that valves in the Auxiliary Feedwater

System required to be locked and/or sealed

were indeed in the

positions required

and controls in evidence.

A test line

isolation valve was found mispositioned

by the inspector

and

was immediately corrected

by the licensee.

It was brought to

the attention of the licensee that this was another'xample

of

the lack of positive control for which the licensee

was recently

issued

an item of noncompliance.

requirements

for procedure

im

4.

Assessment

of 0 eratin

Procedures

During a diesel generator

alignment check on May 14,

1979, the

inspectors

noted that the "automatic voltage set" for the

2AB

diesel generator

was set at 7.2.

The alignment procedure

(2-OHP 4021.032.006,

Revision 2, with Temporary

Change

No. 2)

required the setting to be 5.7.

A review of records indicated

that the diesel

had been last run on May 10,

1979,

and

was

realigned for automatic start using signoff sheet 5.3 of 2-OHP

4021.032.006,

Revision 2, however,

Temporary

Change

No.

2 had

not been

used to change

the value of the setting from 7.2 to

5,7 on the signoff sheet.

As a result,

the operator set the

value at 7.2.

This action would not have rendered

the diesel

generator

inoperable,

but would have

caused it to operate at

a

slightly higher voltage than desired.

This finding represents

apparent

noncompliance with Technical Specification 6.8.1

plementation.

The inspector verified by observation,

review of procedures,

and

discussion with the licensee

(including operators)

that partial

actuation of Safety Injection (one train) is not used routinely to

assist in pressurizer

level control during routine operational

transients;

that in the vent of high pressure

injection, operators

have been instructed to keep

one or more reactor coolant pumps in

operation providing forced flow unless

continued operation would

result in unsafe

or worsening plant conditions; that operators

are

aware of operational criteria for reactor coolant pumps

and have

knowledge of how to identify 50

subcooling in primary loops

as well

0

as saturated

or unsaturated

conditions; that the licensee

does not

have

a procedure for feeding dry steam generators,

however,

the

licensee

did indicate that if all four loops had boiled dry, feed

would be reestablished

to those

steam generators

whose integrity was

known to be intact.

In the event only one or two steam generators

boiled dry, the licensee

would continue to feed those still in

service but would probably not reestablish

flow to the dry ones.

Tagging procedures

do not address

control of tags to assure that

control panel switches,

indicators,

recorders,

etc.

are not obscured.

This potential

does exist in the Control Rooms

due to board layouts.

This matter has been discussed

with the licensee

and administrative

control in this area

has been developed.

No items of noncompliance

or deviations

were identified.

Feedwater Pi in

Cracks

On May 9,

1979, Unit 2 was brought to a cold shutdown condition to

determine

the source of water accumulating in the containment

sump.

Leakage

was originally suspected

to be from the Nonessential

Service

Water System

(NESW) serving containment ventilation coolers.

Investigation

on May 20,

1979, revealed

small leaks in main feedwater

lines to No.

1 and No.

4 steam generators.

Cracks

were found adjacent

to the welds connecting

the feedwater piping to, the steam generator

nozzles.

Subsequent

examinations

indicated

cracks also existed

on

all four loops

on both Unit

1 and Unit 2.

The licensee

informed the

Resident Inspector of the initial findings on May 20,

1979.

The

licensee

has initiated an extensive repair program following the

determination of the cause of cracking,

reported to be high cyclic

fatigue failure.

The Resident Inspector

and

a Region III piping

specialist

are following the repair progress.

A separate,

detailed

report will be submitted at

a later date by the piping specialist.

Source

Rod Location Problem

During the Unit

1 refueling,

new secondary

neutron sources

were

installed in locations

90

removed from the original source

rod

0

assemblies.

Following reactor

head

replacement,

the licensee

received

word from Westinghouse

of a potential problem if source

rods were

placed in certain core locations.

The problem would exist in those

locations with swirl vanes

on the upper core plate.

In these locations,

the hub of the source

rod assemblies

would come in contact with the

swirl vane,

and could result in damage to the source rods, fuel

assembly or swirl vanes

due to the excess

weight resting

on the hub.

The licensee

removed the reactor

head

and thoroughly inspected

the

affected areas.

There

was evidence of contact between the hub and

swirl vanes,

however,

no damage

had occurred.

The affected

assembly

and adjacent

assembly

areas

were inspected for bowing, debris, etc.,

and video tapes

were

made of the inspections.

One adjacent

assembly

had

a tom spacer grid tab which was removed.

The sources

were

moved to adjacent locations in the core which did not have swirl

vanes.

The inspector followed associated

activities including a

review of video tapes

through completion of the transfers

and

inspections.

No items of noncompliance

or deviations

were

identified.

8.

Exit Interview

The inspectors

met with licensee

representatives

(denoted in

Paragraph

1) on May ll, 18, 25,

and June

1,

1979, at the conclusion

of weekly inspections.

The inspectors

summarized

the scope

and

findings of the weekly inspections.

Attachment:

Preliminary

Inspection Findings

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LICENSEE

'merican Electric Power "Svc. Corp.

Xndiana

6 Michigan Power

Company

2 Broadway

.

New Xork, NY

10004

D. C.

Cook Unit 1:

Bridgman,

MX

D. C.

Cook Unit 2

. Bxid man

YX

2.

REGXONAL OFFXCE

U.S. Nuclear Regulatory

Commission

Office of Xnspection

6 Enforcement,

RXXX .

799 Roosevelt

Road

Glen Ellyn, XL'0137

3 '

DOCKET NFiiBERS

50-315

50-316

4.

LXCENSE NUMBERS

5.

DATE OF

XNSPECTXON

'PR-58

.DPR-74

'

~

/F

~

~

p

2 oWF )-ozl ozz.~w

4 z.w

Z

uMz

zz ..~

Il

e

- <zi.

/ 6.; Mithin the scope of the inspection,

no items of noncompliance ox'eviations

were found.

~ ~

7.;: The. following matters are prel'iminary".inspection findings

s'ocFgdo.~f

W

FAISKC-W~~~

8/JSA'C..

/~/.8+*

These preliminary'inspection

indings vi11 be'reviewed

by'NRC

Supervision/'anagemerit

at the Region

XXX Office and they Villcorrespond with you

concerning any enforcement

act"'on.

Nuclear Regulatory

Commission Xnspectox

PRELIMINARY XNSPEC'lION FINDINGS

1.

LICENSEE

2.

REGIONAL OFFICE

American Electric Power Svc. Corp.

Indiana

& Michigan Power

Company

2 Broadway

New York, NY

10004

D. C. Cook Unit 1

(Bridgman, MI)

D. C. Cook Uni

2

(Bridgman, MI)

U.S. Nuclear Regulatory Commission

Office of Inspection

& Enforcement,RIII

799 Roosevelt

Road

Glen Ellyn, XL

60137

3.

DOCKET NUNKS

50-315

50-316

LICENSE NUMBERS

DPR-58

DPR-74

5.

DArE OF INSPECTION

6.

Within the scope of the inspection,

no items of noncompliance or deviations

were found.

8.

These preliminary inspection findings will be reviewed by NRC Supervision/

Management at the Region XII Office and they will correspand with you

concerning

any enforcement action.

Nuclea

Regulatory Commission Xnspector

PRELX

Y INSPECTION FINDINGS

1.

LXCENSEE

2.

RECXONAL OFFXCE

American Elecgric Power Svc.

Coxp.

Xndiana

& Michigan Power

Company

2 Broadway

New York, NY

10004

D.

C.

Cook Unit 1

(Bridgman,

MX)

D. C.

Cook Uni

2

(Bridgman,

MX)

I

3 ~, DOCKET NPiSE.

U.S. Nuclear Regulatory

Commission

Office of Inspection

& Enforcement,RIXX

799 Roosevelt

Road

Glen Ellyn, XL

60137

5.

DYr.E OF INSPECTION

50-315

50-316

DPR-58

DPR>>74

6.

Within the scope of the inspection,

no items of noncompliance or deviations

were found.

7.

The following matters

are preliminary inspection findings:

Q 8.

These preliminary inspection findings will be reviewed by NRC Supervision/

Management at the Region IIX Office and they will correspand with you

concex'ning

any enforcement action.

I

Nucle

Regulatory Commission Xnspector