ML20137L085
| ML20137L085 | |
| Person / Time | |
|---|---|
| Site: | Saint Lucie  |
| Issue date: | 08/08/1995 |
| From: | Bruno T, Perkins J, Ryan L FLORIDA POWER & LIGHT CO. |
| To: | |
| Shared Package | |
| ML17354B293 | List:
|
| References | |
| FOIA-96-485 QAS-PMON-95-5, NUDOCS 9704070152 | |
| Download: ML20137L085 (77) | |
Text
. _
Q.A y
FPL Nuclear Division l
p p t ___._
____ -_ Quality AssuranceludiLReport I
a PMON ACTIVITIES QAS-PMON-95-5 Audit Dates June 1995 1
Audit team:
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L. E. Ryan T. W. Bruno J. B. Perkins j
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QUALITY ASSURANCE AUDIT REPORT -
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---QAS-PMON-95 5 JQA-95-054 To:
L.L. Craig/H. N. Paduano/D. A. Culpepper Date:
August 8,1995 From:
R. A. Symes Department: JNA Subjecii Quiality Assurance Audit June 1995 Performance Monitorine Activities Enclosed for your information is the summary of Perfonnance Monitoring (PMON) activities completed by Juno Beach QA during June 1995. One finding and one Juno Beach Condition Report (JBCR) was issued as a result of this audit.
The finding was discussed at the Post-Audit Conference. Nuclear Information Services (NIS)is responsible to provide this Department with a written response to the finding within 30 calendar days after receipt of this report. The response must provide the following information:
a.
The results of the review and investigation of the finding (s), including identification of probable root cause(s)/ causal factor (s). Analysis should address potential weaknesses in the audited department's self-assessment program which may have impeded the self-identification of the finding and causal factors prior to QA review; l
__b.
A determination of the generic impact of the finding,i.e., whether it extends to other areas, systems, drawings, procedures, etc., or whether it is isolated to those examples cited in the report; Actions taken and/or planned to correct the finding identified and to prevent recurrence of c.
the deficiency. Corrective actions should address the causal factors and enhancements to the audited department's self-assessment program; d.
Date when corrective action was or will be achieved; e.
Identification of the individual (s) responsible for the corrective action.
For corrective actions that cannot be completed within 90 days from the audit report transmittal date, the response shall include:
a.
An explanation why the action cannot be completed within 90 days.
b.
Both the cognizant Vice President / Director and the Vice President Nuclear Assurance on distribution.
The issues covered by the JBCR were also discussed in the Post. Audit Conference and will require corrective action in accordance with IP 803.
P e contact me at 694-4287 if you have any questions.
R.A. Syme.
Quality Man Juno Beach 'ger RAS /ler
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AUDIT REPORT o
QAS-PMON-95-5
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_.______._p TABLE OF CONTENTS EXECUTIVE SUMM ARY.................
2
SUMMARY
OF PMON ACTIVITIES 3
Passport Materials Management Module Introduction (PMON # 1) 3 Finding:
Engineering Quality Instruction requirements are not being adhered to....
5 ASME Code Training (PMON # 2) 6 Design Data Base Input Control (PMON # 3) 8 AUDIT PARTICIPANTS 10 REFERENCES..
12
..e...
PRE-AUDIT CONFERENCE...
12 POST-AUDIT CONFERENCE..........................
12
SUMMARY
OF POST-AUDIT CONFERENCE.
12 SIGNATURES 13 AUDIT DISTRIBUTION.......
14 4
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AUDIT REPORT l
QAS-FMON-95-5
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_ _ _ _ _ _..... _ _ _. _ _.. _. _.. _ _. Ta p or 14~~~~--
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EXECUTIVE
SUMMARY
The associated PMONs were performed to assess the implementation and effectiveness of certain aspects of the FPL.Qualhy Assurance Program. The subjects of the PMONs were design documentation review for Passport Materials Management Module introduction, Component Support & Inspection departmental training, and, design data base input control.
There was one Finding issued: " Engineering Quality Instruction requirements are not being adhered to potentially impacting quality of software produced." See page 5 for additional details.
One Juno Beach Condition Report (JECR) has been written as a result of this PMON addressing issues related to the use of Technical Alerts and the updating and completeness of Engineering Quality Instructions. See pages 8 and 9 for additional details.
Based on the activities and objective evidence audited,it was determined that the requirements of the QA Program were adequately addressed by procedures and the implementation of those procedures was effective except for the specific instances identified.
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AUDIT REPORT QAS-PMON-95-5 L._.
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SUMMARY
OF PMON ACTIVITIES PMON: QAS-NIS-95-1P PassPon Materials Management Module Introduction (PMON # 1)
Lead Auditor: L. E. Ryan
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SUMMARY
This PMON was requested by NIS management to evaluate required software quality assurance design and testing documentation for the nnal phase of the Passport Materials Management Module immediately prior to production release. PMON review activities included an analysis of the following design documentation: Software Requirements Specification (SRS), Software Design Description (SDD),
Software Test Plan (STP), and Software Verificadon & Validation Plan (SVVP).
Based on the processes, interviews and objective evidenc'e observed, the requirements of the FPL Topical Quality Assurance Report are effectively implemented. However, the quality instruction requirement for the development of a Software Verification and Validation Plan has not been implemented for this module. One (1) finding was identified: " Engineering Quality Instruction requirements are not being adhered to potentially impacting the quality of software produced."
DETAILS:
Conformance of the software design documentation to the requirements of the applicable quality instructions were reviewed as follows:
Software Requirements Specification (SRS)
The SRS for this module is called a Requirements Summary. The details of this high level Requirements Summary are contained in the Software Design Description (SDD). The.SRS is at such a high level without the SDD details, it cannot be determined which elements of the required functions are being included in the design. The Requirements Summary was outlined by the auditor to determine the system functionality and to ensure that activities required by the engineering quality instruction are addressed (e.g., performance, attributes, conversions, etc.)
This analysis by the auditor revealed that the i
functionality of the system is adequately addressed.
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Software Design Description (SDD)
The auditor sampled the panel specifications and created functional families of panels and compared them to the mYppg of panels supplied in the SDD. This analysis by the auditor revealed an adequate design for the panels sampled.
AUDIT REPORT QAS-PMON-95-5
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f Software Test Plan (STP)
Two sets of test plans were sampled. The standard panel functionality test (e.g., colors, function keys, etc.) ensures that the panels are consistent throughout the module. The next set of tests ensure that the panels perform the system's functional requirements as designed. The auditor compared the functional tests to the system functionality as described in the Requirements Summary, and found each was addressed adequately.
Software Verification & Validation Plan (SVVP)
As a result of the issuance of a new Engineering quality instruction effective June 30,1994, the requirement for a Software Requirements Report (SRR) and a Software Design Report (SDR) were deleted and the requirement for a Software Verification & Validation Plan was added. The two reports required by the superseded QI ensured that functions were adequately verified from one design document to another (i.e., SRS to SDD). This verification proces,s was to be accomplished in an SVVP per the new QI for each unique project. However, neither an SVVP nor SRR and SDR were prepared to assure correct translation of design requirements (see Finding #1).
Since the Passport Material Management module had not been released for use, the consequences of not preparing an SVVP could not readily be evaluated during the PMON.
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AUDIT REPORT QAS-PMON-95-5
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_ __ _ _. - - -. - - Pag 6of 14 - -- j Finding:
Engineering Quality Instruction requirements are not being adhered to potentially impacting quality of software produced. ~
Criteria:.-
TQR S.0, Instructions, Procedures and Drawings, Rev. 10, 02/01/94, 1 5.1) states in part:
" Activities affecting the qualjty of nuclear safety-related stmetures, systems, and components shall be prescribed by documented instructions, procedures, or drawings of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings...."
ENG-QI 3.7, Computer Software Control, Rev. O,6/30/94 Section 5.3, In-House Developed Software Requirements,14) states in part:
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" Software Validation and Verification Plan (SVVP) shall be prepared to describe the methods / tests which will be used to verify the computer software, Discussion:
During the PMON, a review of the Software design documentation was performed.
The ENG-QI 3.7 requires that an SVVP be prepared to describe the methods which will be utilized to verify the computer software. At the time of the PMON, testing was being performed and design documentation had been approved (Software Design Description) or was being approved (Software Requirements Specification -
Software Requirements Summary along with Software Production Release). An SVVP had not been prepared as required by the QI.
Although a cursory review by the auditor did not identify any missed required functions or testing activities the lack of the SVVP could potentially result in functions not being included in the system or the system not performing properly after production release.
Recommendation:
Your response must address the finding identified above.
The following recommendations are offered for your consideration.
1.
Review actual practices within NIS for verification during the development phase of computer software.
2.
Develop and implement the necessary instructions to ensure that activities affecting quality are properly performed.
3.
Provide formal training to the personnel performing the quality activities.
4 Determine the need for developing an SVVP for this module.
AUDIT REPORT
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QAS-PMON.95-5
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PMON: QAS-CSI-95-4P ASME Code Training (PMON # 2)
Lead Auditor: 'P. W. Bruno
SUMMARY
The implementation of the Component Support & Inspection Group's Departmental Training was evaluated during this PMON. Activities included the participation by the auditor in a one week training course on ASME Section XI.
Based upon the processes, interviews and objective evidence observed, the requirements of Nuclear Engineering's Quality Instruction ENG-QI 6.3 are adequately being implemented by the Component Support & Inspection Group (CSI).
DETAILS:
This PMON was initiated to evaluate the departmental training requirements and responsibilities in the area of continuing training to maintain proficiency in interpretation and implementation of ASME Code requirements. Currently, the CSI Codes & Progra'ms Group performs daily activities involving ASME Section XI as well as other sections of the Code. Nuclear Engineering *s procedures require departmental training to maintain proficiency and satisfactory performance. The methods for accomplishing departmental training include formal internal training
- classes, outside seminars / workshops / conferences / presentations, department / group meetings, day-to-day supervisory interface, reading assignments, checklists and qualification sheets, and videotapes.
As a part of formal training, the CSI Group was provided a course on ASME Section XI, Inservice Inspection of Nuclear Power Plant Components. This course was taught by Reedy Associates,Inc., June 5,1995 through June 9,1995. The auditor was present for the course for the purpose of auditing CSI
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Departmental Training. The review of documentation included a course description, attendance, location, and dates. The documentation contained information that identified persons in attendance with the corresponding lesson plans.
While being primarily an ASME Section XI course Sections I, II, III, V, VII, IX; ANSI B16.5, B16.34, B31.1, B31.7; and Draft Code for Pumps and Valves were introduced as a tie-in to Section XI requirements. Also,10CFR 50.55a was presented.
The following subjects were covered in the training course:
- Organization of Section XI
- General Requirements (scope, classification, etc.)
- Inservice Inspection requirements for Class 1,2, & 3 systems, components, and supports.
- Nondestructive examination, including personnel qualifications
- Inservice Inspection Plans & Schedules
- Application of Code Cases
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AUDIT REPORT QAS-PMON-95-5 ppt _._.___.__.._.___._._..__________
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- Examination requirements and exemptions
- Acceptance criteria & corrective measures
- Flaw evaluations
- Evaluation of-Plant operating events
- Applicability of Section XI to Repair, Replacement, Modification and Maintenance activities.
- Alternative mquimments for small items
- Responsibilities of Owners and Repair / Replacement organizations
- Preparation and content of Repair / Replacement programs and plans
- Verification of acceptability
- Authorized Inspection
- Application of Section XI, Constmetion Code and Code Cases to repair, replacement, and modification activities, including quality assurance, materials, design, welding, heat treatment, examination, and testing requirements
- Design specifications and Design Reports
- Procurement of replacements; reconciliation oflater Editions and Addenda of the Constmetion Code.
4
- Suitability evaluations.
- Defect removal, welding, and special processes
- Installation
. - Examination
- Pressure Testing
- Documentation
- Impact of ASME Code Interpretations
- Relationship of 10CFR50.55a, NRC Bulletins, and NRC Generic Letters 89-09 and 90-05
- Recent proposed changes to the AShE Code
- Relief Requests, including stamping, pressure testing, and inspection.
j The course material consisting of 377 pages was professionally presented by Mr. Rick Swayne who has extensive knowledge in this subject, and has been on the ASME Section XI Subcommittee as well as subcommittees for AShE Sections II, and III.
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O' AUDIT REPORT QAS-PMON-95-5 r F-PL -- - - -
-- Page 8 or 14- --
PMON: QAS-JPN-95-2P Design Data Base Input Control (PMON # 3)
Lead Auditor: J: B. Perkins
SUMMARY
The process to update the Total Equipment Data Base (TEDB), otherwise known as the Passport Equipment Data Module (EDM), was examined. Activities reviewed include those at the Juno Beach Production Engineering Groups (PEG), Plant St. Lucie and Turkey Point Engineering organizations.
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Plant Change / Modification (PC/M) packages and their associated TEDB Change Packages (TCP) were 4
checked against the content of Passport for accuracy of update and completeness of documentation. Thel l
Thanges currently being made to engineering controlled fields by the Procurement Engineering group L were not examined on this PMON.
Based upon the processes, interviews and objective evidence observed, the requirements of the FPL Topical Quality Assurance Report are effectively implemented. However, procedures / instructions do not completely and adequately describe or reflect the processes in use to accomplish TEDB update. JBCR j
95-024 has been written by Nuclear Engineering and Licensing to address procedure /rechnical Alen j
issues.
The PEG and Site Engineering personnel were aware of the procedural requirements, and the documentation supponing the TEDB changes was readily available. The update process evaluated is well documented and is being accomplished with a minimum of backlogged items.
DETAILS:
This PMON was initiated to evaluate the process by which design information, especially that contained in TEDB, is updated from source documents contained in PC/Ms and other design change documentation. ENG-QI 3.6, " Total Equipment Data Base" describes the process and the associated documentation required to change the various TEDB fields controlled by engineering. The St. Lucie PEG also has an additional lower level procedure called PEG-12, "JPN-PSL-PEG Working Instruction -
The Equipment Data Module (EDM) Maintenance and Update Process", rev. O dated 1/27/95. Both of these procedures require the use of a marked up printout (P301) from Passport as the main vehicle of the TCP, While reviewing the hard copy TCP against the data contained in TEDB, it was noted by the auditor that not all of the TEDB information appears on the printout (P301), Thn was_discufs'ed with engineering update personnel and they noted that a Technical Alert was issued in February,19J5 which addresses this issue. The Technical Alert provides an additional procedural step wIich must be followed in order to assure completeness of the information in a TCP. Additionally, two other corrective actions are prescribed in the Technical Alert to effect a permanent solution to this problem; however, these items are not pan of the corrective action system currently in use by Nuclear Engineering &
Licensing. These issues are being addressed in JBCR 95-024 A funher review of the process described in ENG-QI 3.6 revealed the following, which are also
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AUDIT REPORT QAS-FMON-95-5 o.___..__..__ p p L _._.... _ _.__._.__._
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included in JBCR 95-024. Reference is made throughout the initruction to the Manager, Configuration Management; however, this position no longer exists. The responsibilities assigned to this positfon are not addressed in the current instruction. During review of the hard copy TCPs, it was noted that not all of them have a signature in the " Reviewed By" step. This was investigated further and it was discovered that the process was known by the personnel interviewed who were making updates, however, it is not explained in the instmction when this signature is required.
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The review of St. Lucie updates was made by exainining the changes in the TCPs for PC/Ms 082-194, 016-194M,016-194 and parts of PC/M 104-294. The TCP changes were compared to the current TEDB data. Some of the data had been changed since the PC/M was as-built, via other PC/Ms and DCRs. The Review of Turkey Point changes was made by examining the TCPs in PC/Ms91-189,92-002 and 94-120. Of approximately one hundred changes reviewed, only one error was detected in PSL PC/M 016-194M. The error appears to be a typographical error for the " stem lead" value of the Unit 1 MV-09-2 valve operator. This item was corrected via PC/M 016194M TCP during the audit.
A-UDIT REPORT QAS-FMON-95-5
~Page10 tf-14 -----
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AUDIT PARTICIPANTS Name Department / Group A
B C
.-R. Symes JNA/JB X
R. Leckey JNA/JB X
L. Ryan JNA/JB X
X X
T. W. Bruno JNA/JB X
X X
J. B. Perkins JNA/JB X
X X
T. A. Dillard CSI/JB X
M. R. Zokan JPN/JB X
R. J. Filipek JPN/JB X
R.E.NcNe JPN/JB X
X J. P. Brannin JNA/JB X
H. N. Paduano JPN/JB X
W. S. Black NIS/JB X
L. L. Craig NIS/JB X
X T. A. Noyes NIS/JB X
J. L. Venuti NIS/JB X
J. Connor CSI/JB X
X X
E. Anderson CSI/JB X
T. Abbatiello QA/PTN X
P. Basile JPN/JB X
D. Becker JPN/JB X
J. Crum QA/PSL X
R. Custis JPN/JB X
M. Demyanovich NIS/JB X
M. Dixon JPN/JB X
C. Douglas JPN/JB X
G. Gross JPN/PSL X
E. Hill JDC/JB X
P. Hopstein JPN/PSL X
G. Kuhn JPN/FTN X
M. Lacal DC/PTN X
M. Maxwell EUPTN X
l E. McKinney JPN/PSL X
G. Moers JPN/JB X
R. O'Neill NIS/JB X
D. Parker JPN/JB X
R. Pohlman JPN/FTN X
J. Poner JPN/JB X
Key:
A
, Pre-Audit Conference B - Interviewed or Contacted During Audit C - Attended Post-Audit Conference Continued l
O AUDIT REPORT QAS-PMON-95 5 g _ _ _ _ _ _...-_ _ _
.m
_p Name DepartmenUGroup A
B-C
.-J. Reed DC/PTN X
L. Richardson JDC/JB X
D. Richardson ISG/PTN X
A. Segovia JPN/JB X
H. Schelmety JPN/JB X
W. Skelley JPN/JB X
C. Spalter JMC/JB X
K. Sponburgh JMC/JB X
R. Weaver JDC/JB X
D. Wolf JPN/JB X
'B. Woodruff JPN/PTN X
M. Zokan JPN/JB X
Key:
A - Pre-Audit Conference B - Interviewed or Contacted During Audit C - Attended Post-Audit Conference 0
AUDIT REPORT E
QAS-PMON-95-5
_.. F PL - - - - - - -- - - -
-- g g y-REFERENCES 10CFR50, Appendix B FPL Topical Quality Assurance Report, Rev. 41 ENG-QI 3.7, Rev. O, 6/30/95 Computer Software Control 10CFR50.55a ASME Code Sections I, II, III, V, VIII, IX, and y ANSI B16.5, B16.34, B31.1, B31.7 Draft ASME Code for Pumps & Valves FPL Topical Quality Assurance Manual, Rev. 41 JPN Quality Instruction ENG-QI 6.3, Rev. O
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PRE-AUDIT CONFERENCE Pre-Audit Conferences were held prior to individual PMONs. The location and dates are contained in the audit records.
POST-AUDIT CONFERENCE Location:
Juno Beach Date:
July 13,1995
SUMMARY
OF POST-AUDIT CONFERENCE The results of the Performance Monitoring activities were presented to those attending the post audit conference. Note: Informal exit meetings were held at the conclusion of the individual PMONs with appropriate department representatives.
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O AUDIT REPORT QAS-FMON-95-5
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_ _. _ _.. _ _. _ _ -. PigE 13~of~ 14" ~ ~ !
SIGNATURES Lead Auditor:
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W -- 3 ~ W L.E.Ry Date i
Perform ~ e Assessment, Juno Beach Accompanying Auditors:
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Altar 8
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T. W. Bruno '
' Dat'e Performance Assessment, Juno Beach 8-2-AG J. B. Perkins Date Process & Procurement Systems Juno Beach Reviewed By:
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[g Dominic J. Canazaro C
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Supervisor Performance Assessment Approved By:
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s/g/g Quality Managf.}r\\
Robert A. Symds Datb l
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Juno Beach
l AUDIT REPORT 4
QAS-PMON-95-5
-FPL-
--- - __ _. ___ _. - _ _ _-. - Page - M oF M - - -
AUDIT DISTRIBUTI'ON CNRB ADDITIONAL DISTRIBUTION R. J. Acosta J. H. Goldberg W. H. Bohlke T. V. Abbatiello J. E. Geiger L. W. Bladow D. A. Sager R. A. Symes i
T. F. Plunkett D. A. Culpepper G. J. Boissy
- QAD Files w/ Checklist & Audit Plan' Dr. K. R. Craig Health Physics & Chemistry Related Audits Manager Nuclear Health Physics / Chemistry H. N. Paduano Emergency Preparedness Related Audits Dr. W. R. Corcoran Manager - Nuclear Emergency Preparedness Plant General Manager S. E. Scace Nuclear Division Staff Related Audits D. H. West
- CNRB Files Nuclear Trainine Related Audits K. E. Gutowski Manager Nuclear Training Security Related Audits Plant Specific Security Audits
- Manager Nuclear Security Plant General Manager Security Supervisor Nuclear Materials Manacement Related Audits Services Manager Manager Nuclear Materials Management Additional Distribution Fire Protection Audits T. A. Noyes S. Martin. Risk Management K. R. Craig J. T. Luke
- Only Distribution outside the plant D. J. Denver for Security Audits Containing R. S. Kundalkar Safeguards Information B. D. Guilbeault 6/13/95 i
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Title Section Pane i
1 St. Lucie Nuclear Plant Opening 2
St. Lucie Organization Chart introduction 3
3 Refueling Outage Duration Introduction 4
4 Automatic Reactor Trips introduction 5
5 Refueling Activities Operations 10 6
Control Room " Black Board" Annunciators Operations 12 7
Operator using New Data Logger Operations 14 i
8 1B Main Transformer Cooling Fan Breaker Maintenance 17 9
St. Lucie Unit 2 L.P. Rotor Maintenance 18 10 Rosemount Transmit'ter Maintenance 19 11 Plant Work Order Backlog Maintenance 20 i
12 Circuit Board Repair Facility Maintenance 22 13 New Cavity Seal Ring Installation Engineering 26 14 1B Main Transformer Replacement Engineering 27 15 Engineering Jumpers / Lifted Leads -
Engineering 30 16 Engineering PCM Backlog Engineering 31 17 Condenser Cleaning System Engineering 32 18 Biometric Hand Reader Plant Support 37 19 Electronic Dosimeter Radiation Control 41 20 New Automated RCA Entry System Radiation Control 42 21 St. Lucie Plant Cumulative Exposure Radiation Control 44 22 St. Lucie Plant Rad-Waste Volume Buried Radiation Control 45 23 St. Lucie Plant Contaminated Floor Space Radiation Control 46 24 Unit 1 Refueling Outages Radwaste Generation Radiation Control 47-25 St. Lucie Nuclear Plant Management Summary 52 i
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Introduction i
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Overview
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Self-assessment of Plant Performance in Early 1994 Indicated a Need for Change and improvement l
Result was Commitment to Provide Greater Focus on " Core l
Businace". Elements included:
Reduction of Distractors Organizational Changes
" Fresh Perspective"(Fig.2)
Increased Executive Management Oversight Perspective of New Resident Inspectors improved Plant Processes Problem Identification " STAR"(St. Lucie Action Report)
Backlog Reduction On-line Maintenance Program (CMM)
Improved Plant Performance Refueling Outage performance (Fig.3)
. Plant Availability Lost Time injury Rate Automatic Reactor Trips -Area for Improvement in 1995 (Fig.4) 2 l
t St. Lucie Organization Chart Note: This partial organizational chart shows recent changes to Managers i
of SALP areas.
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i Figure 4 5
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Current. Assessment 4
Strong Management Team in Place Focused on Conservative Plant Operation Performance Restored to High Industry Standards l
Emphasis on Continuous improvement Through In-Depth Root Cause Analysis i
i l
Maior Challenges Maintain Consistent High Level of Performance Aggressively Pursue Elimination of Repetitive Problems Safely Conduct Refueling Outages Within Schedule and Budget Remain Cost Competitive with Other Sources of.
i Electrical Generation Address Equipment Obsolescence issues Through On-site Maintenance Capability and Standardization of Components P'repare for Replacement of Unit 1 Steam Generators-1998 Minimize Low Level Waste 6
j.-
i l-l Agenda 4
I i
l Introduction Dave Sager i
l Operations Jim Scarola Maintenance Joe Marchese i
l Engineering Dan Denver i
Plant Support Jeff West j
Radiological Controls Hank Buchanan Management Review Chris Burton 4
Closing Remarks Jerry Goldberg 9
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Operations Major Accomplishments Shutdown and Refueling Operation (Fig.5)
Improved Outage Planning Scope and Safety Sequencing L
Eliminated Refueling Contractor and Enhanced Operator Ownership Health Physics and Reactor Engineering Integrated onto Refueling Crews Increased Oversight During Mid-loopp/$r4'r peration By Additional Management SRO
? 7 Developed and Implempnted Lower Mode Off 1
Normal Procedures
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Added Detailed Shutdown Tests and Inspection to
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Provide Early Detection o" Potantial Problems W-e su - e tsa E14 r
9r Start-up Operation Dedicated Reactivity SRO for Reactor Start-up Improved Reactor, Maintenance, and Engineering Real-time Support aj#,gr.
Strengthened Valve.Line-up and Verification -? g(
Monitoring d"L M Improved System Performance Evaluation During
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Major Accomplishments (conte)
Power Operation Reduced Operator Workarounds
- Clear Expectations on Not Accepting Workarounds
- Captured Workarounds in St. Lucie Action Report
- Improved Engineering Support in Resolving Workarounds Instituted On-line Maintenance Process
- Planned for Less than 50% of LCO
- Contingency Plans Developed
- Risk Assessment via PSA
- Continuous Management Oversight Response to Transients / Decreased Transient Potential Accurate and Prompt Operator Action in All Cases f?'
Developed Infrequent Evolutions Plant Policy #105
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- Re-affirmation of Conservative Operating Philosophy to Avoid First Time Line-ups and Infrequent Evolutions
- Requires Technical Subcommittee be Established
- Requires Facility Review Group (FRG) Review Thorough Root Cause Analysis and Broad Countermeasures in Response to Events Reduce Normally Lit Control Room Annunciators
" Black Board" (Fig.6) 11
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j Operations Current initiatives Strengthen On-going Operations Watch Station Logs Being Improved d6! #
- OwnershipO erator Turnovers are Improving P
j Implementation of Computer Data Loggers to Enhance Equipment Monitoring (Fig.7) j Attention to Detail Being Stressed by Positive Examples i
Increase Personnel Performance i
l Re-affirmed Operations Commitment to the Highest l
Standards of Integrity 1
Implemented 12 Hour Work Limitation Added Psychological Evaluation to Shift Supervisor Selection Process Routinely Reinforce Management Expectations for Conservative Operation Senior Management involved Operators are Fully Empowered and Expected to Take Conservative Actions 13
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Joe Marchese j
Maintenance Manager 15
a Maintenance l
Maior Accomplishments Reduce Equipment Failure / Plant Transients Early Detection Through Predictive Maintenance l
- 1 B Main Transfo'rmer Cooling Power Cables (Fig.8) l Unit 2 Turbine Generator Degraded Bearings j
- 1 A M.G. Set 480v "C" Phase Power Circuit i
"Open"
- Unit 1 Low Pressure Turbine Missing Balance j
Weights (Fig.9) j Utilization of Component Engineers
- Rosemount Transmitters (Fig.10)
Root Cause Capability improvements Bearing Inspection / Failure Analysis On-line Preventative Maintenance Basis increase Equipment Reliability RCP Vibration Monitor Upgrade Valve Standardization Program Turbine Lube Oil Filtration Modification Old Work Order Backlog Reduction (Fig.11) 16
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l 1B MAIN TRANSFORMER 225 AMP COOLING FAN BREAKER.
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Figure 11 20 l
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Maintenance Maior~ Accomplishments (conte)
Implemented On-site Circuit Board Repair Facility (Fig.12)
Refueling /ALARA Improvements
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Installation of Permanent Reactor Cavity Seal Ring j
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Reduced Number of Bolts Required for Refueling l
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F New Underwater Refueling Lighting Resulted in Savings for Each Future Outage
- 15 Man-rem
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. Current Initiatives 4
Personnel Error Reduction l"
Self Checking Vendor Technical Manuale b"" Y,f fa l
l Site Welding Program l
On-Line Maintenance l
Increase Equipment Reliability i
On-line Condenser Cleaning System j
AOV Performance Monitoring I
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Remotely Operated Tool for Reactor Head 0-ring j
Groove Cleaning Upgrade Reactor Stud Handling Tool System 23 i
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24 1
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i-Engineering Major Accomplishments GL-89-10 MOV Test Completion Unit 1-Completed Unit 2-On Schedule Tr q I'
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j Unit 1 Reactor Cavity Seal Ring (Fig.13) l 12 Man-Rem Savings per Outage (Estimated) j Unit 1 Main Transformer Replacement (Fig.14)
Unit 1 Refueling Water Tank Bottom Repair NaOH System Design Deficiency Self Identified via GL 89-10 Testing Design Modified During Unit 1 Outage Extensive Analysis to Determine Consequences increased Use of Risk Analysis Application to On-line Maintenance Training of Engineering and Plant Personnel S
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Maior Accomplishments (conte) 4 improved Plant Support
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Operator Workaround Resolution l
- Identification and Tracking l
- Prioritization
- Closure I
As-Required Packages (ARPs) i
- Efficient Process for Component Replacements
- Quicker Turnaround for Maintenance Maintenance Specifications
- 18 Issued to Date
- Communicates Design Basis 28
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1 Current initiatives inconel 600 - Nozzles and Steam Generator Plugs I
Unit 1 Steam Generator Replacement g v'(d'c)g'p i
CAD Redraw of Principal Drawings p
i Jumper and Lifted Lead Reduction (Fig.15) 6d w
j Plant Change Backlog Reduction (Fig.16)
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Integrated Safeguards Testing
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M Total Numberof J/LLs E J/LLs > 18 Months Old Figure 15 30
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Fire Protection Emergency Planning Security Training Je= West Services Manager 33
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l' Plant Support Fire Protection i
Maior Accomplishments Improved Fire System Reliability i
j System Maintenance and Testing l
- Replacement of Section of Underground Fire Main I
- Upgrade Fire Barriers and Doors Training
- Implementation of New Burn Building I
Current initiatives i
Resolution of Thermo-lag Issues
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l Emergancy Preparedness l
Maior Accomplishments Development of Core Melt Model for Simulator Communications Upgrades l
Backup to HF System Telephone Capability via Satellite l
Pager Backup to Autodialer System i
Response to Emergency Facilities l
Accountability Drill i
j Interim Recovery Managers i
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Teams Emergency Action Level Enhancements
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Security Maior Accomplishments l
Installation of BIOMETRICS System (Fig.18)
Current initiatives i
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Reduce Loggable Events l
. Vital Door Control l
Security System Reliability Lost Key Cards Design Basis Vehicle Threat System Implementation h
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Maior Accomplishments Re-accreditation of Operations Training Programs l
Licensed Operator Examination Results 100% Pass Rate on Initial Exams,8 SRO and 2 RO Greater than 90% Pass Rate on Requalification Exam's Enhanced Maintenance Training Materials and Mock-ups Revised Technical Training to include Interactive Techniques Revised 10 CFR 20 Integrated Training Personnelinto Line Groups During Outages Current initiatives Re-accredit Maintenance and Technical Programs Development of Engineering and Site Personnel Coritinue Use of Simulator to Support Operations Procedure Development
- Lower Mode Procedures
- Validate Safeguards Procedures
- Blackout Procedure Practice Plant Evolutions on Simulator Prior to Their Implementation in Plant.
A Instituted Computer Based Training 38
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l Radiological Controls i
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i Hank Buchanan Health P1ysics Su aervisor 39
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I Radiological Controls Maior Accomplishments Implemented Revised 10 CFR 20 Procedures Training
- Health Physics Personnel
- Plant Staff i
l ALARA TEDE (Exposure Reduction)
Extensive Pre-job Planning Mock-up Training Reactor Disassembly / Reassembly 4
Air-conditioned Reactor Containment Building During Refueling Outage ALARA Technology (Exposure Reduction)
Replaced Direct Reading Dosimeters with Electronic Dosimetry (Fig.19)
- N.I.S.T. Primary Calibration
- Lowell University N-16 Study Automated Entry Sy' stem (Fig.20)
- Real Time Dose
- Integrated Radiation Work Permits 40
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Maior Accomplishments (conte)
ALARA Technology (cont'd) l Telemetry l
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- Continuous Air Monitors l
Communications
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- 25 Full Control Video Cameras l
- Enhanced Audio Systems 1
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- Mobile Robot with Video / Audio /Teledose
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1994 Exposure Below Target by 96 Man-Rem (Fig.21) l i
ALARA Rad-Waste Rad-waste Buried Remained Low in 1994 (Fig.22)
Introduced Steel Grit Blast System (Metal i
Decontamination)
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Reduced Contaminated Areas to 1600 Sq. Ft. (Fig.23) s Formed Teams for Rad-waste Reduction (Fig.24)
- Identified Sources of Dry Active Waste (D.A.W.)
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- Implemented Counter Measures 43 d
St. Lucie Plant Cumulative Exposure i
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1994 Actual 44 Figure 21
St. Lucie Plant Rad-Waste Volume Buried 18000
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l St. Lucie Plant Contaminated Roor Space 12000-i 10000 l
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Number of 5100 Square 4674 l
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St. Lucie Plant Unit #1 Refueling Outages Radwaste Generation I
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4 J
Radiological Controls i
i Current initiatives i
All-Electronic Dosimetry System by 1/1/96 i
l Complete Integration of Technology Innovations 1
l Prepare for Barnwell Closure Finalize / Build Resin Storage Facility j
Zero Rad-waste Inventory by 12/1/95 ALARA TEDE (Exposure Reduction) l Explore Source Term Reduction Opportunities j
Increase Team Pre-job Planning Efforts t
i ALARA Rad-waste Non-depleting incores New Training for Plant Staff Research New Technologies
- Use of Water Dissolvable Material I
l 48
Management Summary G
C7ris Burton
?' ant General N anager 49
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I Management Summary Maior Accomplishments Heightened Safety Culture Conservative Operating Philosophy 4
Policy on Infrequent Lineups i
l Use/ Knowledge of PSA (On-line Maintenance l
Process)
Avoid Single Point Vulnerability Circumstances Jop Management involvement in Problem Solving Through sytf STAR Process implementation v
P' NaOH lssue Resolution j
g,:
t Operator Workaround Awareness improved Workforce Morale 12 Hour Operator Shift Limitation Developing Worker Versatility (cross-training)
Union / Management Cooperation Workforce Aware and Appreciative of Plant Goals i
Candid Communications on Plant Efficiency
\\
50 i
i
a-
~
l Management Summary Current Initiatives Depth of Root Cause Analysis Improved via Management l
Daily Review of STARS (St. Lucie Action Reports)
Analysis Assigned to Appropriate, Dedicated Individual or Team 4
Root Cause Reviewed by~ Management j
Team Prior to Determination of Corrective l
Actions l
Increase Effective Trending and Follow-up on Event Causes Handled via Standardization of Cause Codes for i
LERs, lHEs, HPEs, STARS i
- Quarterly Trend Reports Reviewed by Plant I
Management Assignments as Appropriate for Further Corrective Actions Strengthen Corrective Actions Technical Subcommittee Probes any Technical Specification Issue and Reports Results to Facility Review Group 51
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I St. Lucie Nuclear Plant (Figure 25) 52 d,
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Closing Remarks i
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Jerry Goldberg i
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ST. LUCIE NUCLEAR PLANT SELF ASSESSMENT 2
CLOSING REMARKS Having heard today's presentation a little more than a week ago and i
reflecting on St. Lucie's performance during this particular SALP evaluation period, I would like to share with you my sense of where I see the program today and where I believe it is headed in the foreseeable future.
)
f As you heard earlier the St. Lucie management team, who customarily j
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received "attaboys" from industry contemporaries and regulators in days gone by, was not satisfied with plant performance in early 1994. We were j
i having too many equipment and personnel issues which signaled we were getting complacent. A likely reason for this development was due to key i
management positions being filled by the same people for many years;.
some as long as 7 years. As a result, we have undertaken a significant number of key management changes to bring fresh perspective to the job.
And we are not sitting back assuming that good people will last forever. We 4
are improving the quality of our operations support management by affording.them equivalent licensed operator training. To sustain our future needs for qualified professionals, we are adding six " June Graduate" 54
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engineers (three at St. Lucie, three at Turkey Point) each year.
a We have also overhauled our basic administrative system of problem
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identification and resolution by introducing the STAR Program. This I;
program replaces a number of old redundant programs which were a i
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holdover from construction days. As a result, we now have a more comprehensive system which helps to expedite the handling of both
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problem identification and problem resolution.
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I With regard to problem solving, the root cause analysis of a false j
engineered safeguards signal last fall on Unit #1 during plant startup l
l following a refueling outage, uncovered a new significant systemic problem l
with Rosemount pressure transmitters. The uncovering of this problem, 1
l which involved a mixup of stainless and monel diaphragms at the f
j transmitter factory, was further complimented by the development of a f
j gamma backscatter technique in FPL's materials laboratory which enabled I
quick reliable verification of what type of diaphragm was installed in each l
transmitter.
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t" Our management team today is more sensitive to the need for conservative decision making which is evidenced by their determination to avoid plant operations utilizing unfamiliar plant configurations; their recent response to a serious operator error; and their efforts to eliminate operator work-arounds insofar as possible. This reduction of operator work-arounds is being undertaken in a number of ways. Maintenance backlogs are being attacked aggressively to maintain the plants in a high state of material readiness.
Operators are flagging for engineering action, plant performance problems that indicate a need for technical assessment. Engineering is being tasked by management to solve stubborn technical issues which have added unreasonable demands for operator attention over the years.
i FPL Intends to continue to build on the St. Lucie improvements highlighted here today. Accordingly, I am confident that St. Lucie will remain one of the top performing U.S. nuclear stations in the years that lie ahead.
56
2 Florida Power & Light Company List of Participants i
i Name Position Phone (407)
Sager, Dave V.P., St. Lucie Nuclear Plant 468-4100 i
l Bohlke, Bill V.P., Engineering & Licensing 694-3241 l
Geiger, Jim V.P., Nuclear Assurance 694-4630 i
i Burton, Chris Plant General Manager 468-4106 j
Scarola, Jim Operatir>ns Manager 468-4103 j
Marchese, Joe Maintenance Manager 468-4254 l
Dawson, Bob Licensing Manager 468-4107 l
Denver, Dan.
Site Engineering Manager 468-4108 i
West, Jeff Services Manager 468-4226 l
Bladow, Wes Site Quality Manager 468-4190 Buchanan, Hank Health Physics Supervisor 468-4171 57
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Produced by:
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Information Services Dept.
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