ML20151L637

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Submits Background Info for Meeting W/Util to Discuss Status of Programs to Improve Engineering Activities for Plant. Significant Weaknesses Identified in Engineering Activities, as Described by Listed Points
ML20151L637
Person / Time
Site: Arkansas Nuclear  Entergy icon.png
Issue date: 07/28/1988
From: Calvo J
Office of Nuclear Reactor Regulation
To: Martin T
Office of Nuclear Reactor Regulation
References
NUDOCS 8808040099
Download: ML20151L637 (11)
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[a nog jo,, UNITED STATES NUCLEAR REGULATORY GUMMISSION WASHINGTON, D. C. 20555 ]

,  % :j July 28,1988 i

I NOTE T0: Thomas T. Martin l Acting Associate Director for Inspection and Technical Assessment Office of Nuclear Reactor Regulation UTILITY: ' ARKANSAS POWER & LIGHT COMPANY-PLANTS: Arkansas Nuclear One - Russellville, AR ANO-1 (B&W PWR)

ANO-2(CEPWR)

SUBJECT:

BACKGROUND FOR MEETING PURPOSE: OPPORTUNITY TO MEET AP&L SITE AND CORPORATE ENGINEERING MANAGERS AND TO DISCUSS THE STATUS OF PROGRAMS TO IMPROVE AP&L ENGINEERING ACTIVITIES FOR ANO During the past few years, significant weaknesses have been identified in engineering activities at Arkansas Nuclear 0- , as described by the following points:

The 7/84 - 6/85 SALP Board report emphasized the need for the licensee to improve their design change process in all phases.

The SSFI on the ANO-1 Emergency Feeuwater (EFW) System in Jan-Feb 1986 identified significant deficiencies in the safety reviews of design changes, design calculations for battery sizing and motor operated valve torgue switch settings, post modification testing of

, the station batteries, some EFW valve IST, and drawing control.

One finding from the SSFI involving an inadequate safety review of a design modification (to delete the check valves from the two steam supply headers to the turbine driven EFW pump) resulted in escalated enforcement with a $50,000 civil penalty.

The 7/85 - 12/86 SALP Board Report emphasized the need for the licensee to improve performance in the areas of design change l control, accuracy of drawings, quality of safety evaluations, and reduction of backlogs in closing out design change packages, '

engineering evaluations, and drawing changes.

The ANO-1 containment temperature issues identified in August 1987 resulted in escalated enforcement with a $100,000 civil penalty  ;

against Criterion XVI of Appendix B. The licensee had known of the l condition since initial startup in 1974, but had not taken adequate i corrective action nor reported it to the NRC. Temperatures as high as 183*F were routine at power; the FSAR stated 110*F as normal at power bulk temperature. Also, EQ calculations assumed 120'F ambient j l

8808040099 880728 j@l l PDR ADOCK 05000313 if p PDC

Thomas T. Martin July 28,1988 temperature. The licensee had not evaluated the effect of the high temperature on structures, components, and accident analysis results. Neither had the effect on environmental qualification been evaluated.

In 1985 soleniod containment isolation valves in the post accident sampling system (PASS) for Unit 2 were found installed backwards, which would allow containment pressure to unseat them. The Unit 2 problem was corrected promptly; however, a similar deficiency was also noted in the Unit 1 PASS system. A DCP was issued about a year later to correct the problem. In December 1987 the licensee realized the DCP had not been accomplished yet. A thorough evaluation of all containment penetration isolation valves identified one more backwards solenoid valve in the Hydrogen analyzer system. In addition previous local leak testing of these valves was detennined to have been inadequate.

During the SALP period just ended (1/87 - 6/88) on two occasions the SRI noted instances where a temporary modification with a 50.59 evaluation was warranted, but not done.

Deficiencies in configuration control and design calculations of seismic supports have been identified over the pact few years. One of the more significant examples was a Unit 1 EFW support inside containment, which had been missing since initial construction.

Some of AP&Ls efforts to improve their engineering performance are sumarized below:

Formal training and certification program for persons designated to perform 50.59 reviews.

The new Plant Vodification Manual and new procedures establishing the design change process have been implemented.

Design Engineering was reorganized and is now entirely within the I Nuclear Operations organization.

Isometric drawing upgrade project was begun in 1987.

J Plant engineering was reorganized:

Plant modifications works for plant manager.

Site engineering reports directly to senior site management.

Progress has been made in reducing the DCP closecut and drawing )

update backlog. j The NRC staff believes that AP&L needs to strengthen their engineering capabilities; we also recognize the improvement efforts that AP&L has undertaken.

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Thomas T. Martin July 29,1988 As stated in the attached agenda, the AP&L engineering managers plan to discuss various improvement programs and the progress made. Resumes for George Jones, Design Engineering General Manager (Corporate) and Rick Lane, ANO Engineering Manager (Site) and a meeting schedule are also attached.

d$ bb Jose A. Calvo, Director Project Directorate - IV Division of Reactor Projects - III, IV, Y and Special Projects Office of Nuclear Reactor Regulation Attachments:

1. Meeting Agenda
2. Resumes
3. Meeting Schedule l

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ENGINEERING ORGANIZATION DESIGN ENGINEERING

  • Reassignment of Corporate Engineering to Nuclear Operations
  • Restructuring of Design Engineering
  • Development of Nuclear Engineering within Design Engineering I l

PLANT ENGINEERING

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  • Fire Protection / Prevention Integration e LLRT/ILRT Integration ,

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  • Steam Generation Integrity Program l
  • Engineering Support Group

- PM Program

- Technical Manuals

- Equipment Data Base . I 1

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- Q List

  • System Engineering l

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AL 26 '83 09:34 @&L _ _ 180.110 VATS CENT P.3 kYaC/! met / /

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DESIGN PROCESS IMPROVEMENTS I

  • Design Basis Consolidation l e Design Control Process Improvement Initiatives

- Implementation of Plant Modification Manual j

- Quality of Design and Design Documents

- Work Load Management - Priority Setting l

  • Lead Engineering Review
  • Individual Development Program

+ Design Document Improvements

  • Temporary Hodification Process 1

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I'"8' 1 MAJOR INITIATIVES 1

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  • Design Basis Upgrade
  • Internally Conducted SSFI
  • Individual Development Program
  • Isometric Update
  • Secondary Pipe Wall Thinning Program
  • Welding Program
  • Station Priority Review Committee l

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, . _ _ _ a g.m n n n g ,a w a v.rd RESUME FOR SRC EXPERIENCE AND COMPETENCE SERVICE

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'. I . George T. Jones '

/]h fa II. Arkansas Power & Light - General Manager, Design Engineering '

. I I,I . . B.S. Mechanicil Engineering,' University of Alabama - I

, IV. BWR-4 System and Simulator '

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Certificat.f on Certified NDE RT, PT Level II "

V. N/A 3

VI. WORK EXPERIENCE >

January 4, 1988 - Present ARKANSAS POWER & LIGHT COMPANY i

GENERAL MNAGER, DESIGN ENGINEERE kesponsible for the direction of Mechanical, Instrumentation and Controls, Electrical, Nuclear, Structural and Civil Design

  • Engineering to: '
  • Ensure proper design and modiftetten of equipment / system
  • Ensure required reports, speciffcations, and contract procedures are developed and maintained
  • Ensure proper implementation of Design Control Programs
  • Ensure completion of projects and objectives as sensduled
  • Ensure procedural and regulatory compliance of activities within ,

Design Engineering .

1 September, 1985 - January 4, 1988 l DANIEL INTERNATIONAL CORPORATION PROJECT MANAGER Assigned to the General Service Agreement for AP&L's Arkansas Nuclear One Power Plant. Supervised work consisting of Administrative, Personnel, Payroll, Planners, Quality control. Industrial Safety, Craft Supervision and Craft to execute modification and maintenance support.

. July 1975 September 1985 TENNESSEE VALLF.Y AUTHORITY PLANT MANAGiri. BROWNS FERRY NUCLEAR (October 1981 - 5eptember 1985) ~-

Assigned on-site responsibility for safe operation of a three unit Boiling Water Reactor Electric Generating Station. Responsible for all aspects of operation including Security. Health Physics, Personnel and Administration Quality Assurance, Plant Engineering, 4; Perfonnance Engineering, Nuclear Engineering, Testing, Regulatory N Compliance Industrial Safety. Fire Protection, Operation, Maintenance, Modification, and Planning and Scheduling.

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.."* AS5!STANT BRANCH CHIEF ' Outage Manacement Branch

. - (January 1980 - October 1981) ~

ggg Assigned direct rupervision of the Central Planning and Scheduling Group and the Modification Control Group. Responsible for the /# ^M : '

development and maintenance of integrated modification and maintenance schedules, long range schedules and refueling outage schedules forfivereactors(toosites). .,

3 Supervision of project manager / engineers in the development of .

' plans, schedules and budgets. Assumed direct supervision of Outage Directors in the absence of the. Board Chief.

i OUTAGE DIRECTOR BROWNS FERRY NUCLEAR '

(February 1978 - January 1980) ,

Responsible for planning, detailvd scheduling, and. execution of refueling outages, major maintenance, and modification at the three unit BWR site. Provided functional and administrative 3 supervision to Administrative, Engineering, Management Personnel.

Trades and Labor employees. Responsible for erformance of work force in the areas of Regulatory Compliance, salth Physics, l 1

Quality Assurance, Security Field Engineering, Modification  !

Control. Nondestructive Testing, Performance Testing. '

_p 0WER PLANT MAINTENANCE _SpECIALITY (ENGINEER)

(July 1975 - February 1978) l Assigned responsibility for developing procedures and providing engineering direction of activities required for refueling and modification to bofling water reactor. These activities included maintenanceandmodificationofreactorvessel(includinginternals). -

valves. HVAC, condensor and heat exchangers, snubber and containment vessel and auxiliaries. Performed NDE as Certified Inspector.

supervised welding activities. Assigned for six months to an ERDA project in cooperation with General Electric to study refueling outages to improve methods, equipment and tooling, management controls.

February 1970 - July 1975 COMBUSTION ENGINEERING-FOSSIL DIV.

SENIOR DESIGN ENGINEER (January 1974-July 1975)

Assigned to Chief Engineer's staff to resolve manufacturing discrepancies and develop and maintain engineering design standards for pressure part manufactured to ASME code. $srved as engineering interface

, among Desfgn,' Manufacturing, Welding & Metalurgy.

_ DESIGN ENGINEER (February 1970'-January 1974)

Perfonned engineering design of power piping, structural support, ducting and component selection for fossil fuel power boflers. -

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JUL 22 '88 11:15 AP&L ____ _ _ _110. NOVATS CENT p.4 AlltCbm Cd.2 RESUMI 0F RICK LANE ga j

_ EXPERIENCE 1

1 5/12/86 to Present Mannser. AN0 Insinsering

. Arkansas Power & Light Company f Frovide engineering & technical support onsite to p,lant staff.

11/17/77 to 5/12/86 Nanager, Mechanical Engineering Arkansas Power & Light Company Frovide engineering & technical support to both nuclear & fossil plants.

7/29/76 to 11/17/77 Supervisor. Prod. Mechanical Arkansas Power 6 Light Company Supervised the mechanical & civil projset angineering interface with 3echtel Fever Corporation.

5/9/74 to 7/29/76 Asst Project Supervisor, Fred.

Irkansas Power & Light Company l Supervised the mechanical & civil project engineering interface with 1scheel Fever Corporation.

6/1/72 to 5/9/74 Asst. Instneer Arkansas Fever & Light Company Fritar11y responsible for the nuclear steam supply interface with Cenbustion Engineering.

EDUCATION 38ME. University of Arkansas, Fayettaville, Arkansas -- 1968-1972

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Attachment 3 l

l SCHEDULE FOR MEETING WITH ARKANSAS POWER & LIGHT Engineering Managers on July 29, 1988, Room 128-9 9:00 AM Dennis M. Crutchfield Lester S. Rubenstein Jose A. Calvo 10:00 AM Thomas T. Martin CONTACT: Craig Harbuck X21344 '

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f Thomas T. Martin July 28,1988 As stated in the attached agenda, the AP&L engineering managers plan to discuss various improvement programs and the progress made. Resumes for George Jones, Design Engineering General Manager (Corporate) and Rick Lane, ANO Engineering Manager (Site) and a meeting schedule are also attached.

ORIGINAL SIGNED BY JOSE A. CALVQ Jose A. Calvo, Director Project Directorate - IV Division of Reactor Projects - III, IV, Y and Special Projects Office of Nuclear Reactor Regulation Attachments:

1. Meeting Agenda
2. Resumes
3. Meeting Schedule DISTRIBUTION iCentral-File '

PD4 R/F JCalvo CHarbuck 0FC :PMIMI :PD4:D  :  :  : .

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NAME :CHarbuck:kb :JCalvo  :  :  :  :  :

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DATE :07/2f /88w :0_7/4/88  :  :  :  :  : ~

0FFICIAL RECORD COPY

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