ML20209F780
| ML20209F780 | |
| Person / Time | |
|---|---|
| Site: | Palisades  |
| Issue date: | 01/28/1987 |
| From: | Roy G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | Donoghue STONE & WEBSTER ENGINEERING CORP. |
| Shared Package | |
| ML20209F786 | List: |
| References | |
| NUDOCS 8702050194 | |
| Download: ML20209F780 (47) | |
Text
v
. JAN :: 81987 54 -Ef.f Stone & Webster Engineering Corporation 1875 Eye Street N.W., Suite 550 Washington, D,C.
20006
DearMr.Donoghue:
In response to your letter of January 15, 1987, enclosed are copies of the handouts used during the meeting in this office on January 8 with Consumers Power concerning the. Palisades plant.
Sincerely yours, frTcjfM1!.Irpjt>y U.h 11.14y Gen W. Roy, Director Division of Resource Management and Administration
Enclosures:
As stated cc w/ enclosures and ltr dtd 01/15/87:
DCS/RSB(RIDS)
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P fSJ GWRoy/rw CE elius 01/28/87 01
/87
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PRESENTATION TO THE NUCLEAR l
REGULATORY COMMISSION l
l ON THE l
PLANNED RESTART OF THE 1
PALISADES PLANT BY CONSUMERS POWER COMPANY JANUARY 14,1987 w,
a n n
~.. -
a CONSUMERS POWER PARTICIPANTS IN PRESENTATION Dr William McCormick, Jr, Chairman and CEO Dr Frederick Buckman, Vice President, Nuclear Operations j
Mr Joseph Firlit, Plant General Manager OTHER COMPANY EXECUTIVES IN i
ATTENDANCE l
i Mr Jack Reynolds, Executive Vice President, Energ Supply Mr Gerald Slade, Executive Director, Quality Assurance Mr Robert Rice, Plant Operations Manager Mr Richard Orosz, Engineering and Maintenance Manager i Mr David Joos, Planning and Administrativ Manager e
l
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_ OUTLINE OF PRESENTATION introduction, Recent History and Overview e
- McCormick Palisades Plant issues and Resolutions
- Buckman Testing and Restart Program e
- Firlit Summary e
1
- Buckman
a o
P INTRODUCTION AND RECENT HIS Palisades Plant performance has been uneven e
throughout its history.
While plant performance in 1983 was improvin e
severe financial difficulties of Consumers Power, beginning in 1984 with Midland Plant shutdown resulted in certain problems.
- Deteriorating maintenance
- High personnel turnover e
New plant top management installed at end of 1984 began new cycle of improvement.
90% capacity factor during 1985 operation e
New Consumers Power CEO elected in November of 1985 and new Vice President, Nuclear Operations in February 1986
- - - ' - * ~ - " " * ^ " ~ ' ' ' ~ ~ ~ ~
l
!NTRODUCTION AND RECENT HIST i
(Contd) 1
'e New management embarked upon programs to:
Improve safety i
Improve reliability Restore material condition l
Improve training Reduce turnover Improve management The plant tripped on May 19,1986 with some e
equipment problems during shutdown.
As a result, Consumers Power Company embarked t
upon an accelerated effort to address:
i Trip-related problems Overall plant material condition 1
i i
Design-related issues that emerged during l
the outage
.I
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o INTRODUCTION AND RECENT (Contd) i Consumers Power Company management
'e believes the plant will be ready for restart 1
soon.
We have:
Resolved and tested trip-related problems Extensively investigated and improved plant j
material condition and improved the plant Maintenance Program i
Resolved all design-related issues
^
o I
i 1
MAJOR PLANT ACCOMPLISHMENTS Maintenance work orders reduced from 4 e
1984, to 2350 in 1985, to 1077 in 1986 l
Eight-week inventory Control Room deficiencies reduced from 16 1984, to 65 in 1985, to 7 at present i
Streamlined plant management while increasing e
maintenance personnel i
.. -................ ~.... -. -
- - - " ~ " ~ " ~
i i
OTHER MAJOR PLANT ACCOMPLISHMENTS Reduced radwaste production from 18,000 cubic e
feet in 1984, to 12,000 cubic feet in 1985, to less than 7,000 cubic feet in 1986 INPO training / accreditation of 5 programs in e
December 1985, others awaiting INPO action i
I j
Employee turnover reduced from 17% annually e
in 1984 to 3% in 1986 j
j Established Fitness for Duty Program in 1986 e
l with unnanounced, random drugIalcohol testing, with each employee being tested at least twice a year Achieved the best safety record; the safest e
combined gas / electric utility in the United States i
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l PALISADES PLANT ISSUES l
- MATERIAL CONDITION MAY 19 TRIP PROBLEMS l
DESIGN-RELATED ISSUES i
I I
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i
a i
PLANT MATERIAL CONDITION i
l e
Plant material condition had deteriorated because of:
j
- Employee turnover and poor morale
- Quantity and quality of maintenance performed
- Organizational and programmatic weaknesses i
Consumers Power Company recognized need and e
initiated efforts to improve material condition in 1984 to:
i
- Assure plant and equipment reliability i
- Minimize operator work-arounds and distractions
- Reduce work order inventory to a desirable level l
l i
l l
l
O PLANT MATERIAL CONDITION (Contd) l RESOLUTION
[*
Actions initiated Prior To May 19 Event:
- Nuclear Operations Department Reorganization
- Maintenance Order Task Force
- Maintenance Inventory Reduction
- Systems Engineer Program
- Systems Assessment Program
- Advanced Maintenance Management System
- Operational Readiness Assessment
- Preventive Maintenance Program
- Competitive Salary Program J
MAY 19,1986 TRIP e
Equipment issues
- EHC Power Supplies
- Primary Coolant Charging Pump P-55A
- Pressurizer Spray Valve CV-1059
- Letdown Back-Pressure Regulator CV-2012
- Turbine Bypass Valve CV-0511
- Atmospheric Steam Dump Valve CV-0779 May 19,1986 plant trip emphasized need to e
expand and accelerate the improvement effort
i ACTIONS DURING CURRENT OUTAGE e Material Condition Task Force i
e improved Maintenance Program i
e improved Material Condition e
Extensive Testing Program e
System Functional Evaluation 1
f l
MATERIAL CONDITION IMPROVEMENT PR CONTROL CORRECTIVE OPEN ROOM ACTION i
WORK DEFICIENCIES SYSTEM ORDERS p
p WORK SYSTEM ENGR.
ORDER INTERVIEWS HISTORY N
MATERIAL CONDITION OPERATOR INTERVIEWS PLANT TASK FORCE TRIP HISTORY OPERATOR CONCERN LIST OPERATIONAL l
READINESS ASSESSMENT MAY 19 TRIP PROBLEMS i
I Y
MATERIAL CONDITION CONCERNS l
v i
EXECUTIVE MGMT/
PLANT REVIEW COMMITTEE REVIEW
, _.. -. - _ -. _, _,. _ _. ~., _ _ _,. _ _ _.
i 1
l PLANT MATERIAL CONDITION i
l l
CRITERIA FOR ACTION ITEM TIMING 1
l e
Prior To Start-Up Repair all deficiencies which relate to proper system operation l
Perform comprehensive testing program l
Initiate accelerated inspections and preventive l
maintenance to enhance reliability Prior To End of Next Refueling Outage e
p Perform modifications or maintenance to enhance long-term reliability e
include in Five-Year Plan Reliability or maintainability enhancements which require additional evaluation for effectiveness and cost justification
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0 PLANT MATERIAL CONDITION (Contd)
RESULTS e
222 issues identified e
14 issues Required No Action e
159 Issues Resolved Prior To Start-Up e
49 issues To Be Addressed After Start-UP 39 issues will be addressed before the end of the 1988 REFOUT i
10 issues will be incorporated into the Five-Year Plan
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~.~.; T.J..~ T,;.:...; l T JT JJ.:J..J.~....... 1.......f..T..::::.~.T..^.Z.~.~.T..J J....~....T~......J PLANT MATERIAL CONDITION (Contd)
BREAKDOWN OF ISSUES SCHEDULED TO BE ADDRESSED AFTER PLANT START-UP l
2 Modifications to improve ability to maintain or i
inspect i,
15 Modifications / equipment upgrades to decrease maintenance requirements i
3 Development of contingency plans 3
Equipment reolacements to improve spare l
parts availabiity j
2 Development or acceleration of PM activities 2
Maintenance / modification to reduce support time / effort required of operators, security personnel, etc 12 Modifications / upgrades to improve long-term l
reliability i
l l
6 Evaluations of equipment performance to define possible reliability improvements i
i l
4 Equipment operability improvements i
i l
l 49 Total
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IMPROVED MAINTENANCE PROGRAM ACTIONS COMPLETED 1
Operations Reorganization To Enhance e
Maintenance Diagnosis and Prioritization Enhanced Post Maintenance Testing e
e increased Mechanical Maintenance Work Force i
From 38 to 57 l
Streamlined Maintenance Organization e
Increased Use of Contractors To Supplement e
Plant Expertise Instituted Plant Training Staff of 4 People for e
Electrical and Mechanical Repairmen
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l IMPROVED MAINTENANCE PROGRAM (Contd) i ACTIONS IN PROGRESS Accelerated Preventive Maintenance Program e
implementation Accelerated implementation of Equipment Monitoring and Performance Trending i
Comprehensive Valve Maintenance Program e
INPO Accreditation in Electrical and Mechanical o
Training Programs System Engineer Training Program e
L
......................................:...:...-.............=:..
^ - - - - ^ ^
IMPROVED MAINTENANCE PROGRAM (Contd)
RESULTS o
Excellent Heatup in November
- Low Primary Coolant System Leak Rate (Less Than 0.1 gpm)
- Few Rework Requirements - 270 Work Orders Tested, 5 Required Rework e
improved Operator Confidence
- System Function
- Maintenance Process e
Expected Payoff
- Plant Availability
- System Reliability
- Safety System Challenges l
PAllSADES OPEN WORK ORDERS 4,250 4000*
4,000 3,750 3,500 p
3,250 E
3,000 w
2,750 a
z 2,500 g
2354 2,000 u.o 5
1,750 m2
.1,500 1,250 1077 1,000 i
750 500 l
250 -
l 0
984 1985 1986
- ESTIMATED l
l
~ " " " " ~ " ' '
' ' ~ " " ' ~ " ~
~
8 OPEN WORK ORDERS Total open work orders 1077 Post maintenance testing 208 Completed 53 Total active work orders 816 Preventive maintenance 75 Inspections 7
Adjustments / calibrations 59 Spare equipment 12 Subtotal-corrective work orders 663 Corrective work orders Valves / valve operators 241 Gauges / indicators / switches 140 Heaters / ventilators 69 Pumps 66
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Compressors / heat exchangers 36 i
Motors 34 i
Equipment / facilities l
33 I
Miscellaneous 26 Tanks 18 r
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CONTROL ROOM DEFICIENCIES 161 160 150 140 130 120
,W Uz 100 E
UC w
90 O
u.
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80 oc w
Sll 3
70 a
2 65 60 50 40 l
30
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20 l
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10 7
0 1984 1985 1986 i
JUMPER LINK AND BYPASS STATUS 80 1
72 d
~
70
_63 E
60 h
E d
50 50 z
46 E
~
43 0
40 u.o 30 1
3 2
23 24
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20
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JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC 1986 MONTHLY VALUES' I
I
t 5
DESIGN-RELATED ISSUES CONFORMANCE TO DESIGN Low-Pressure Safety injection Pump - Low Flow e
Component Cooling Water System - Undersized e
Heat Excharigers x
Service Water System - Low Flow e
ADEQUACY OF DESIGN 3 Half-Capacity Service Water Pumps e
RAS Logic Failure on Loss of DC e
SSFl Identified items Recirculation Actuation System Lock-in Positive Control of Valves With Dual Position t
Safety Function High-Pressure Air / Low-Pressure Air Interface l
l Non-Q Breakers for Safety Service
q.................__...
l RESOLUTION OF DESIGN-RELATED ISSUES All Known issues Will Be Resolved Prior To e
Start-Up Multilevel Approach To Safety Assurance e
Development and implementation of Comprehensive Pump Testing Program Development and Performance of Comprehensive System Functional Evaluation Development of integrated Test Program Development of an improved Configuration Management Program
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PUMP TEST PROGRAM OBJECTIVES Address generic concern following LPSI pump e
P-678 findings Verify performance of safety-related pumps to e
FSAR requirements x'
e Provide head curves to support system testing and balancing as required SCOPE Service Water Pumps P-7A, B, C Auxiliary Feedwater Pumps P-8A, B, C i
Component Cooling Water Pumps P-52A, B, C Charging Pumps P-5SA, B, C e
Containment Spray Pumps P-54A, B, C e
Low-Pressure Safety injection P-67A, 8 e
High-Pressure Safety injection P-66A, 8 o
F STATUS e
Complete r
l-__.-.._,.-_-.-.---..__..-..._....-_,._--.--_.
- ^
i SYSTEM FUNCTIONAL EVALUATION OBJECTIVE Verify system performance to support normal o
operat, ion and critical safety function success paths SCOPE All systems required for normal plant operation e
or entical safety function success path and their supporting systems (26 systems)
STATUS Evaluation is complete and exceptions have e
been identified.
All discrepancies will be dispositioned through testing or engineering justification prior to start-up.
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SYSTEM FUNCTIONAL EVALUATION SYSTEM OPERATING REQUIREMENTS
/
3 NORMAL OPERATIONS POST-ACCIDENT SYSTEM MAINTENANCE FSAR /
OPERATING FSAR AND PROCEDURES TECHNICAL ACCIDENT MAINTENANCE MODIFICATIONS SPECIFICATIONS
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MODIFICATIONS TEST REQUIREMENTS
1..........:...........11..........
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1 TEST PROGRAM OBJECTIVES Assure proper operation of safety and other important systems in normal operating and post-accident modes by:
Verify open issues from System Functional e
Evaluation Ie Complete Technical Specifications Surveillance Tests Complete Augmented Surveillance Tests e
Complete Post Maintenance Testing e
Perform integrated system testing for selected e
systems
TEST PROGRAM (Contd)
SCOPE Cold Shutdown Testing e
Hot Shutdown Testing e
i Power Escalation Testing e
4 STATUS Substantial Cold / Hot Shutdown Testing e
complete Program / Procedures to address System e
Functional Evaluation open items to be complete mid-January Post Maintenance Testing for approximately e
200 work orders remains open Integrated System Test Plans under e
development for six (6) systems
TEST PROGRAM 1.
SFE TEST REQUIREMENTS 1
I l
AUGMENTED INTEGRATED HEAT-UP SURVEILLANCE AND POWER ASCENSION SYSTEM TESTING i
y SURVEILLANCE T
l TESTS
~
PROGRAM POST I
MAINTENANCE l
TESTS
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CONFIGURATION MANAGEMENT PROGRAM OBJECTIVES Reconstruct well-documented design basis e
Verify plant configuration conforms to design e
Improve administrative controls that maintain e
plant design i
Ensure adequacy of design basis through SSFl e
type reviews SCOPE Still under development.
Will include:
e FSAR Drawings and Procedures Test Program 1
Spare Parts Program I
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CONFIGURATION MANAGEMENT PROGRAM (Contd)
STATUS 6AsY e
Project Manager assigned Scope, process and schedule to be developed e
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Y March 31,1987 b
p)n b
Phased approach planned to address important e
systems first Estimated 2 -3 yearsfor_ full program e
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RESTART SCHEDULE Plant Heat-Up to Hot Shutdown Late January on T & fe !>r %7 i
Heat-Up and Hot Shutdown 7
2-1 Weeks Testing x
Plant On-Line Early February T Power Escalation Testing 100% Power Operation s
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STATUS REVIEW ACTIONS COMPLETED Repaired May 19 Equipment Problems e
Material Condition Review and Upgrade e
System Functional Evaluatioq'k: 44 pd*)
e t
Pump Testing Program e
increased Maintenance Work Force e
Streamlined Operations and Maintenance e
Departments
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EXAMPLE DESIGN-RELATED ISSUES Low Pressure Safety injection Pump Impellers Service Water System e
Component Cooling Water Heat Exchangers o
Recirculation Actuation System Seal-in Air-Operated Valve Design Deficiencies e
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..............................._....... ~._............................ 1.J....
EXAMPLE OF MCTF INITIATED ACTIVITY COMPONENT COOLING WATER HEAT EXCHANGERS ISSUE The CCW heat exchangers are undersized by 30%.
Normal system lineups during certain plant condi-tions result in high differential pressure across the heat exchangers.
i ACTIONS Completed:
I e
Independent firm was contracted to evaluate l
acceptability of 4500 gpm flow through heat exchanger.
Heat exchanger tubes cleaned and eddy-current i
tested impact of reduced CCW flow to shutdown e
cooling heat exchanger evaluated - new I
containment pressure / temperature profiles produced System testing and balancing completed e
1 l
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(
EXAMPLE OF MCTF INITIATED ACTIVITY COMPONENT COOLING WATER SYSTEM (Contd)
Operator procedures and checklists modified; o
training conducted Deferred:
le Heat exchanger replacement or capacity addition Deferral due to engineering and parts lead time e
JUSTIFICATION FOR OPERATION Analysis demonstrates that the system will perform its safety functions with reduced flow rates.
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EXAMPLE OF SSFI INITIATED ACTIVITY RECIRCULATION ACTUATION SIGNAL
[ RAS) SEAL-IN DESCRIPTION SIRW tank low-level recirculation actuation does not seal-in.
This could result in the output signal reversing itself.
There may then be insufficient air i
to handle the cycling valves.
ACTIONS Completed:
Revised Emergency Operating Procedures e
Reviewed other significant safety-related auto e
actuation circuits for potential seal-in problems.
Prior to Start-Up:
Complete the RAS seal-in modification.
Long Term:
Consider modifying the 2400-volt fast transfer o
circuitry.
l
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EXAMPLE OF SSFI INITIATED ACTIVITY RECIRCULATION ACTUATION SIGNAL (RAS) SEAL-IN (Contd) i GENERIC l
l Other actuation circuits reviewed for seal-in problems.
l d
EXAMPLE OF SSFI INITIATED ACTIVITY RECIRCULATION ACTUATION SIGNAL FRASD SEAL-IN L
(Contd)
GENERIC Other actuation circuits reviewed for seal-in problems.
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f-i EXAMPLE OF PUMP TESTING INITIATED ACTIVITY SERVICE WATER SYSTEM ISSUES Service water pump performance inadequate e
e System balancing inadequate e
Lake water temperature occasionally exceeds 75* F design value.
i Service water flow inadequate during DBA with e
failure of one diesel generator ACTIONS l
Completed:
Service water pump impeller modifications e
Modifications to assure adequate flows to post-l accident loads with:
I failure of either diesel generator l
failure of instrument air l
l
- -. :. :....... ~..
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EXAMPLE OF PUMP TESTING INITIATED ACTIVITY SERVICE WATER SYSTEM (Contd)
System testingIbalancing e
Technical Specification change submittal to e
provide for fire water backup on loss of 1 -2 diesel generator Deferred:
Addition of service water capacity above e
original plant design to:
provide adequate post-accident flow with failure of either diesel generator without operator action allow for reinstatement of fourth containment air cooler allow for higher lake water temperature Deferral due to engineering and parts lead time e
EXAMPLE OF PUMP TESTING INITIATED ACTIVITY SERVICE WATER SYSTEM (Contd)
JUSTIFICATION FOR OPERATION Analysis shows that the system will perform its safety functions as currently configured with administrative limits on plant operation at elevated lake water temperatures.
Required operator actions have been reviewed.
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PIPE WALL THINNING INSPECTIO PROGRAM e
OBJECTIVES I
Establish baseline data for a permanent program Identify any areas of immediate concern 1
Address concerns related to Surry Plant incident e
SCOPE Ultrasonic techniques Secondary side points, most susceptible to erosion / corrosion e
STATUS 1
In progress, will be complete by January 31, 1987 i
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