Text

Commonwealth Edison Briefing to NRR Personnel
	ML20058A981
Person / Time
Site:	Dresden, Byron, Braidwood, Quad Cities, Zion, LaSalle
Issue date:	11/16/1993
From:	Wallace M; COMMONWEALTH EDISON CO.
To:	;
References
	NUDOCS 9312010341
	Download: ML20058A981 (38)
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Michael J..Wallace Vice President and Chief Nuclear Officer u

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Unit Performance (Prior to Start of Dual Unit Outage)

> Unit 1 - 278 day run

Unit 2 - 224 day run Union / Management Relationship Turnaround

Mutually Supportive

> Ongoing Work Practice Improvements l

Needs i

Complete Dual Unit Outage l

One Additional Outage on Each Unit

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'1992 Unit Performance

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- Unit 1 - 372 Days (Jan '92 - Feb '93)

-- Unit 2 - 290 Days (July '92 - May '93)

1993 Unit Performance

Unit 1 - on 205 D_ay Run

> Unit 2 - One extended run; 104 Days r

l Safe Man Hours

>10.Million Plus Manhours without a Lost Time Accident

Outage l Performance

Completed 60 Day Scheduled Outage in 52 Days

Personnel Errors

> Slight increase in Personnel Error Rate

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>Three extended runs; 135 Days,145 Days,179 Days

Outage Performance

Completed 60 Day Scheduled Outage in 58 Days

Current Steam Generator Outage

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Two extended runs; 158 days,107 days Equipment improvement Plans

Two Major Outages on each Unit

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- Fall '94 (Spring '95) - Condensate Motors, Feedwater Motors, Recirculation Motors

- Spring '96 - Condensate Motors, Feedwater

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- Spring '94 - Condensate Motors, Feedwater Motor, Reactor Water Cleanup Motor

- Fall '95 - Recirculation Motor, Condensate Motors, Feedwater Motors

> Unit 1 Dry Cask Storage

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= 1993 Unit Performance J

Two extended runs; 141 Days,146 Days

LaSalle Business Development Team (23 Individuals; 11 weeks)

Objectives

/ Assess performance in Operations, Maintenance, and Engineering

/ Assess effectiveness of site and corporate QV

/ Assess quality and effectiveness of site administrative and control programs

/ Assist in identification of Root Causes

Scheduled Completion Week of December 13,1993.

Team includes Both Management and Union Members

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Committed to immediate Change and Long Term Performance improvement

- Established Short Term and Mid-Term Targets

Planned Actions implemented To:

- Resolve'long standing equipment problems

- Remove barriers to effective operation of the Units

- Establish new standards for materiel condition

- Accelerate MOV dP testing

1993 Maintenance Outages Scheduled For Each Unit

- Demonstrate commitm'ent to upgrade plant materiel condition

- Perform corrective and preventive rnaintenance to improve reliability of safety systems

- Perform preventive and corrective maintenance on EDGs

- Address safety system equipment issues

- Gather data on specific issues to develop solutions to known problems

>1994 Refuel Outages

- Extended fours weeks

- Recover significant level of-safety margin for systems and components

- Complete corrective actions for long standing equipment problems

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Characteristics

- Focus on Restoration of Safety Margin

- Establish Corrective Action Culture

- Self' identify Problems 4

- Analyze for Root Cause

- Fix Promptly

> Resolution of Know issues

- Motor Operated Valves

- Vulnerability Assessment

- Operability Assessment Process

>Self Identification of Problems

- Integrated Reporting Program

- Integrated Quality Evaluation

- Quality Oversight Effectiveness c> Build Capability for Corrective Action Culture

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)L Attachment A Quad Cities Station

)

Completed Short Term Actions 1993

)

Long Standing Equipment Problems

Toxic Gas Monitor - Resolution of spurious isolation of Control Room HVAC system.

Safe Shutdown Makeup Pump - Resolution of pump room high temperature conditions.

Service Water Radiation Monitor - Resolution of silting problems.

)

Operator Work-Arounds 48 issues identified and prioritized by operators. Issues which have been resolved

=

include:

1 A Recirculation temperature recorder k

1B Instrument Air compressor relief valve Unit 1 EGC Unit 2 Turbine expansion recorder i

Unit 2 Torus pressure recorder Joy air compressor relief valve Control Room toxic gas analyzer

)

Control Room HVAC Materiel Condition

Materiel Condition / Housekeeping Supervisor position established and manned.

)

Area reclamation schedule established.

RHR/RHR Service Water System (RHRSW) 1 A RHR Service Water Vault upgraded (the remaining Unit 1 vaults will be completed by the end of 1993, and the Unit 2 vaults will be completed by the end of 1994).

)_

1 A,10, and 2C RHRSW pumps overhauled; remaining RHRSW pumps scheduled for overhaul.

i Motor Operated Valve (MOV) Differential Pressure Testing e

Nine GL 8910 MOVs have been dP tested since August'1993 1

Unit 1,1001-18A & B (LPCI minimum flow) valves.

Unit 1,1001-348 and Unit 2,1001-34A & B (Torus return isolation) valves.

Unit 1,1301-60 (RCIC minimum flow) and 1301-62 (RCIC cooling water) valves.

Unit 1, 2301-3 (HPCI steam admission) and 2301-14 (HPCI minimum flow) valves.

)

4

1 Attachment B

)-

Quad Cities Station Planned Corrective Actions 1993 Maintenance Outages

)

Prominent activities which are scheduled include:

(VA T/SSPITitems are italicized and highlighted as bold)

InstaHation of MSL vibration sensors.

)

InstaHation of RVLIS modification for non-condensible gas issue (NRC BuHetin 93-03).

Pressure test of the Unit 1 Core Spray testable check valves 9A & B.

InstaHation of feedwater nozzle taps for flow element calibration.

Replacement of existing feedwater flow transmitters with high accuracy Rosemounts.

)

Modification of Unit 2 RFPlow suction trip logic to 'two-out-of-two' with time delay.

InstaHation of ground cable on SRMs/iRMs.

Replacement / repair of SBLC heat trace.

Replacement of four (4) Unit 1 Rosemount transmitters (this will complete

)

replacement activities for Bulletin 90-01 Supplement 1 on both Unit.1 and 2).

Implementation of planned safety system preventive and corrective maintenance activities on EDG, HPCI, RHR and RCIC (activities are delineated later in this section).

)

Emergency Diesel Generators (EDGs) and AC Power Replacement of the Unit 1 DGCWP (au others were previously replaced).

Replacement of Unit 1 Reserve Aux Transformer (TR-12).

Replacement of all20 engine powerpacks on the Unit 1 and Unit 2 EDGs.

nstallation of field ground indication modification on Unit 1.

3 instaHation of modification on Unit 1 and 2 EDG fuel oilsystem to aHow for flexible hose instaHation.

Inspection of current transformers in local dieselgenerator panels (Unit 1 and Unit 2).

InstaHatlon of new digital tachometer instruments on local dieselgenerator

)

panels (Unit 1 and Unit 2).

High Pressure Coolant injection (HPCI)

Differential pressure (dP) testing of the Unit 2 2301-3 valve (steam 31 admission valve).

)

Attachment B (cont.)

)

Inspection / refurbishment of Unit 1 motor speed changer (MSC) and motor gear unit, and the Unit 2 motor gear unit (Unit 2 MSC previously inspected).

Replacement of motors on Unit 1 2301-36 and Unit 2 2301-35 valves (torus suction).

Replacement of current Gemac flow andpressure transmitters to Rosemount Y

models.

Replacement of various air operated valve diaphragms (preventive maintenance).

Replacement of obsolete oilpressure switches with new models.

Upgrade of drain pot level switches (GE SIL 531).

Replacement of stem on Unit 2 2301-15 (test return) valve.

)

Repair of Unit 1 turbine-pump coupling.

Alignment check (" cold") of the Unit 2 turbine-pump.

Reactor Core Isolation Cooling (RCIC)

Upgrade of drain pot leve! switches (GE SiL b31).

Upgrade of rupture disc (Unit 2).

Replacement of motors on the Unit 1 1301-48 & 49 (pump discharge) valves, and the Unit 21301-60 valve.

Replacement of various air-operated valve diaphragms (preventive

)

maintenance).

Inspection of barometric condenserintemals.

Residual Heat Removal (RHR) and RHR Service Water (RHRSW) y' Differential Pressure (dP) testing of the Unit 1 1001-16A&B and Unit 2 4

1001-16A (heat exchanger bypass) valves, Unit 1 and Unit 21001-28A&B and 1001-29A&B (LPCI injection) valves, the Unit 21001-18A&B (minimum flow) valves, and the Unit 1 1001-37A&B (torus spray shutoff) valves.

Replacement of motor pinion, worm shaft gears, and motors for Unit 1 1001-34A and Unit 21001-34B (Torus return isolation) valves.

Replacement of gearing on Unit 1 1001-238 valve and 1001-268 (drywell

)

spray ) valves.

Replacement of gearing on Unit 21001-23A and 1001-26A (drywell spray).

valves.

Modification of the control circuitry of the Unit 1 and Unit 21001-16A&B valves to " seal-in" logic.

y Replacement of the yoke to actuator bolts (upgrade) on the Unit 1 1001-28A&B (injection) valves.

]

i

)

Attachment B (cont.)

)'

Replacement of the yoke to bonnet bolts on the Unit 21001-26A (containment spray) valve, and the Unit 21001-198 (crosstie) valve.

Replacement of obsolete room cooler thermostats for the RHR rooms with environmentally qualified temperatuna switches.

Refurbishment of RHRSW 1D and 2D pump motors.

j

)

Core Spray (CS)

I i

Installation and balance of new motor-pump coupling for 18 pump.

)-

)

I

)-

)

i 1

i

)

J

. 1 w-

)

Attachment C l

Quad Cities Station l

)

Planned Corrective Actions 1994 Refuel Outages

)

1l

)

Unit 1, Spring 1994 (Q1R13)

Overhaul of RCIC Turbine and upgrade of Rupture Disc.

I Implementation of HPCI Steam Line Drain and steam exhaust line Sparger modification.

{

)

Trim upgrade on selected Core Spray, RHR, and HPCI valves to alleviate i

cavitation and vibration.

Refurbishment on RHR Service Water and Recirculation pump motors.

Overhaul of Core Spray pump.

Installation of Varistors in 250 vDC valve motors.

Overhaul of 1 A RHR pump.

Replacement of the RHR -298 stem materia!

Implementation of RHR Heat Exchanger maintenance activities.

Continuation of MOV dP Testing.

\\

Unit 2. Fall 1994 (02R13)

HPCI Cutwater modification and permalign analysis.

Resolution of Main Steam Line vibration /Electromatic Relief Valve issues.

Refurbishment of two RHR and two RHRSW pump motors.

Alignment of Feedwater, 2A Core Spray, and Condensate pumps.

Trim upgrade on selected Core Spray, and RHR valves to alleviate cavitation

-i

)

and vibration. (selected HPCI valves were previously upgraded).

Anchorment of Electromatic Relief Valve discharge piping.

RCIC high exhaust pressure setpoint trip.

Continuation of MOV dP testing.

Reactor Water Cleanup return piping replacement.

)

Completion of the HPCI steam exhaust line sparger modification.

)

)-

l h

Attachment D Quad Cities Station 7

Achieving Sustained Excellence Characteristics 3

Focus on Restoration of Safety Margin Establish a Corrective Action Culture Self-identification and analysis of problems Prompt response and action on issues 3

Resolution of Known issues Motor Operated Valves

17 valves have been dP tested, including 12 high priority valves.

15 valves will be dP tested during Maintenance outages, including 9 high priority valves.

MOV dP testing will be completed by end of 1994.

J Vulnerability Assessment (VAT)

80 VAT issues will be resolved by the en" of 1993.

119 additional VAT issues will be resolved by the end of 1994.

)

Operability Acsessment Process

Benchmarking activities were conducted at Waterford.

Now process developed and implemented by station.

3

The proper attitude and environment will be established at the station.

Self Ider,tification of Problems Integrated Reporting Program 3

Implemented in August 1993.

Identification of problems has doubled since implementation.

Root Cause Analysis training continuss:

55 individuals have completed training.

)

Failure analysis training scheduled (FPI)

D-

i

).-

1

1 Attachment D (cont.)

'.)-

Senior Management oversight ensures proper level of investiga' tion.

)

Operability Assessment Process integrated into problem j

identification scieening Integrated Quality Evaluation (lQE)

)

Process to monitor performance and conduct self assessments.

Demonstrated as an effective tool at Zion Station.

Piloted at Quad Cities Station in October 1993.

)

Quality Oversight Effectiveness l

t

Senior Nuclear Operations Division Director assigne to head Site l

Quality Verification (SQV)

)

Will provide more effective focus and assertive resolution of f

issues.

Resources for SQV were increased.

O i

Build Capability for Corrective Action Culture l

Engineering Improvements y

Benchrr o,g activities at Monticello by System Engineering,

'nd Operations personnel.

Mainten

System t:nwa aring Stpervisor extended assignment at Monticello to accomplish in-depth benchmarking.

Maintenance Strategy implementation Establishes System Engineer as' System Manager Defines Objective performance goal for key Risk-significant systems.

)

System Engineer Mentors position established.

?

i

Quad Cities Station Site Vice President Site Vice President *l R. Pleniewicz Executive Asst.

G.Tietz I

I I

I Station Manager Support Services Director Site H. R. Supvisor Reg. Assurance Supv.

Site Eng.

G CampbeQ J. Kudalis Financial S. Simpson N. Chrissotimos

& Const.

asa Services 1GS3 Manager Director R. Moravec J. Sirovy Training Supv.

A. Chernick 11/93

~

Quad Cities Station Manager 1

l Station Manager G.Campben 8/93 Exec. Asst.

A. Lewis 9/93 I

i i

i I

Operations Manager Maintenance Supt.

Work Control Supt.

Long Range W. C. Supt.

Technical Services Supt.

H. Hentschel T. Kron W. McGaffigan R. Zrubek L. Tucker f

11/93 11/93 S'93 7/93 Shift Ops. Supv.

D. Cook 11/93

O

i Overal1 Nuclear Operations

]

O-i O

'O i

i O

Actions, Plans and Resources O

4 O

l O-

.o

-_~-_

Improve Nuclear Operations Performance by Focusing On:

e Increased Personal Accountability e

Clearer Expectations for Performance e

Improved Communications e

Clearer Definition of Organizational Roles e

" Management Issues" e

Increased " Management Effectiveness" e

Improving Leadership e

Improving Planning

u v

v v

u u

w Talent - S aort Term Outside Search for Site Vice Presidents eSig Berg

- Naval Academy Graduate

- Graduate Work in Organizational Change e Mike Lyster

- 32 Years Naval / Utility Experience

- VP Nuclear - Cleveland Electric eWarren Murphy

- 31 Years Research/ Utility Experience

- Senior VP - Vermont Yankee Nuclear Power

~

Talent: - Shor: Term continued eOutside Search For Station Managers

> Guy Campbell, Quad Cities

- Extensive Industry Experience

- GM Ops and Plant Support - Savannah River

> Don Ray, LaSalle

- 28 Years Nuclear Experience

- Plant Manager - Connecticut Yankee eOutside Search For Quad Cities Technical Superintendent

Larry Tucker

- Extensive Industry Experience

- General Supervisor, Plant Engineering - Calvert Cliffs eOngoing Outside Searches

> Zion Operations Manager

> System Engineers for All Sites

m v

v v

v

.v v

c Human Resources Long Term Improvemen~:s

Management / Leadership

- Objective - Create more effective Leaders and Managers

- Action - Formalized training through 1995

Improved' Union / Management Relationship

- Objective - Cooperative, collaborative relationship focused on cost competitiveness

- Action:

- Two sessions held with Union Presidents and Senior Management

- Mutual Gains Bargaining-Workshop scheduled for December,1993

- Several progressive work practice pilots underway

v

- v u

- m v

v v

.v

v:

Process Improvements eObjective

- Achieve and Sustain Significant Improvement

- Significantly Lower O&M Costs

- Considerably improve Materiel Condition

- Foster a Culture of Continuous Improvement eThree Step Approach

- Process Re-engineering and Recommendations

- Implement In a Paced, Planned Process

- Post-Implementation Results Measurement and Re-evaluation eStep One Completed

- Work Control

-- Chemistry

- Health Physics eStep One Underway

- Security

- Emergency Preparedness-

- Maintenance and System Engineering

m m

Wor 1 Process Improvement Schedule l

1993 1994 l

l lQ 2Q 3Q 4Q IQ 2Q 3Q 4Q Work Control

1 h -'~

i t

i Chemistry d

i i

'1 R

Health Physics

(

Security C

l l

i 6

i i

Emergency Preparedness a

i t

i l

Maintenance and Systems Engineering i

a F u Operations i

i Engineering and Construction m

Training l

Business Services Human Resources I

Performance Monitoring and Improvement C

Nuclear Oversight /QA_

w Nuclear Regulatory Services l

Materiels Management l

Management Information Systems, and Office Support Step 1 - Process Reengineering and Reconunendations Step 2 - Implementation i

I Step 3 - Post-Implementation Results Measurement and Re-Evaluation

~

Plant Improvement Overall Approach

Do as much as we can, as fast as we can 1

- but

Plan improvements at a pace where success can be reasonably assured,

- then

Determine resource requirements (People and S)

~

m

~

v

~

w.

Outage Sclec u e 1993 -1997 1993 1994 1995 1996 1997 A1R04 A1ROS A1R06 Braidwood 1 lIA1F24 1-1 i

i t

i A2R03 A2R04 A2R05 A2R06 Braidwood 2 O

I i

i i

O B1R05 B1R06 B1R07 B1R08 O

O Byron 1 B2R04

, B2R05 B2R06 F l Byron 2 D2R13 D2R14 D2R15hl Dresden 2 ED D3R13 D3R14 (a3R15 Dresden 3 m D3F15

[: p.i L1R05 L1R06 L1R07 L1R08 LaSalla -

DE L1F19 E L1F22 1

-1 I-I i

-l L2R05 L2R06 L2R07 LaSall o

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l u

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'IRefuel Outage -

Forced OutageM Maintenance Outage neu" Good Plant" Status Achieved

u

~

Commonweal: 7 Eclison O&M Ex3ense 1983 -1993 Millions 21% Average annualincrease from 1200

.1986 through 1992 ^ - - -

923 916 000

. 18% Average driridel iricrease - - - - - - - - - - - - - - - - 76b ' ' '

~

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800

,p

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Braidwood 649 523

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......................404 320 302 300 f!f 400 22 9..

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5 1 9-7 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 E9 Actual OBudget muTarget New Units Enter O&M Budget in: By1-85, By2-87, Br1-87, Br2-88 (Prior Years not inflated to 1993 dollars)

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