IR 05000285/1989014

Insp Rept 50-285/89-14 on 890306-10.No Violations or Deviations Noted.Major Areas Inspected:Licensee Tech Spec Required Calibr Program & Preventative Maint Program Re Unaddressed Component Plant Instrumentation Calibr

ML20248E430
Person / Time
Site:	Fort Calhoun
Issue date:	03/30/1989
From:	Andrea Johnson, Stetka T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20248E420	List: IR 05000285/1989014 ML20248E417
References
50-285-89-14, NUDOCS 8904120242
Download: ML20248E430 (7)

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l APPENDIX U.S. NUCLEAR REGULATORY COMMISSION REGION IV l NRC Inspection Report: 50-285/89-14 Operating License: DRP-40 Docket: 50-285 Licensee: Omaha Public Power District (0 PPD)

1623 Harney Street Omaha, Nebraska 68102 Facility Name: Fort Calhoun Station (FCS)

Inspection At: FCS, Fort Calhoun, Washington County, Nebraska l Inspection Conducted: March 6-10, 1989 j Inspector: you .

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R. Johnson' Reactor Inspector, Plfnt

, Date i SystemsSection,DivisionofReacyorSafety O

Approved: \%4;o [ . -

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T. F. Stetka, Chief, Plant Systems Sec//1on Date Division of Reactor Safety r Inspection Summary Inspectinn Conducted March 6-10, 1989 (Report 50-285/89-14)

Areas Inspected: Routine, unannounced inspection of the licensee's Technical Specification (TS) required calibration program, and the preventive maintenance (PM) program related to the calibration of plant instrumentation for components not addressed in the T Results: Within the areas inspected, no violations or deviatior.s were identified.

l l The licensee's plant surveillance (PS) calibration program for the control and

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evaluation of installed instrumentation and control (I&C) devices, specified by ,

the TS, is effectively being implemented and no weaknesses were noted. The licensee's preventive maintenance (PM) calibration program for the contrcl and l evaluation of installed IaC devices not addressed in the TS, is effectively being implemente PDR ADOCK 05000285 O PDC

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DETAILS Persons Contacted j OPPD

• K. Morris, Division Manager, Nuclear Operations

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• W. Gates, Manager, FCS

• R. Jaworski, Manager, Station Engineering

• K. Miller, Supervisor, Maintenance q

• C. Sininons, Licensing Engineer i

• C Brunnert, Supervisor, Operations Quality Assurance { '

l *R. Kellogg, Supervisor, Special Services

• A. Hyde, Supervisor, Technical dupport J. Foley, Supervisor, Instrumentation and Controls R. Connor, Supervisor Electrical Maintenance J. Drahota, Supervisor, Maintenance D. Golden, Systems Support Engineer D. Hendry, Special Services Engineer '

US NRC l

l *P. Harrell, Senior Resident Inspector

• T. Reis, Resident Inspector l

• Denotes personnel attending exit intervie The NRC inspector also contacted other operations, engineering, and l

administrative personne . Followup on Previous Inspection Items 2.1 (Closed) Unresolved Item (285/8717-01): OPPD Procedure MP-MOV-3A,

" Calibration and Adjustments of Motor Operator Gate and Globe Valves" was identified as permitting setting of the Limitorque motor operator's (M0s)

torque switches at values which exceed the design limits. The licensee's

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revision to this procedure (MP-MOV-3A, Revision 3) has been implemented and i now considers total thrust values (e.g., . . . thrust at torque switch l settings plus inertial thrust). The total thrust values are based on not exceeding the manufacturers design limits plus a 10 percent margin. The procedural change precludes the torque switch settings of all SMB-00 operators being set too high for gate and globe valve applications. The revision to MP-MOV-3A also ensures that practices have been accomplished which will prevent the M0 overthrust occurrences described in NRC Information Bulletin (IN) 85-0 .2 (Closed) Violation (285/8717-02): This violation involved the licensee's failure to identify and evaluate an as-found overthrust condition in Limitorque M0s. At the time of the 87-17 NRC inspection, the licensee took steos to perform a preliminary stress analysis, based on fatigue

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i testing the worst-case loading conditions. The licensee had indicated that a-subsequent final analysis, to evaluate the impact on the expected )

. life, would be accomplishe q The eight M0s for the high pressure safety injection (HPSI) pumps were viewed as being acceptable with regard to structural integrity and 1 operability. .The licensee's corrective action, at the time of the NRC )

inspection, required a review of allowable thrust limits on all l safety-related Limitorque M0 l The NRC inspector, during this inspection, reviewed the following ,

licensee's documentation with regards to his preliminary root cause J investigation as follows: 1 1'

MOVATS Incorporated Signature Analysis Valve Report for OPPD Fort Calhoun Station Unit-1: 4

Test I.D. 285-050 487-HCV-311 June 4, 1987)

Test I.D. 285-052 187-HCV-312 June 22, 1987)

Test I.D. 285-052 287-HCV-314 June 5, 1987)

Test I.D. 285-050 487-HCV-315 June 5 1987)

Test I.D. 285-050 287-HCV-317 June 5, 1987)

Test I.D. 285-050 287-HCV-318 June 19, 1987 Test I.D. 285-042 487-HCV-320 June 12, 1987

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Test I.D. 285-052 587-HCV-321 June 19, 1987 l

l Overload Cycle Test Report for Critical Components SMB-00 Limitorque Operators, Kalsi Engineering Incorporated, December 1,1987

NPPD Response to NRC Information Bulletin (IB) 85-03, dated May 15, 1986

Table 1, Valve Operator Information, M0 VATS Testing, 1985

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OPPD Interoffice Memorandums with Regards IB 85-03, 1985 through 1987 l

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Maintenance Orders (Selected, 1985 through 1987)

Maintenance Procedure MP-MOV-3A, Revision 2, December 1988 l

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Maintenance Procedure MP-MOV-3B, Revision 0, March 30, 1987

• Maintenance Procedure HP-MOV-3C, Revision 0, March 31, 1987

Maintenance Procedure HP-MOV-1, Revision 7 April 3, 1987

• Maintenance Procedure MP-MOV-3, Revision 1, October 28, 1985

MOVATS Testing Procedures for MOs HCV-311, 312, 314, 315, 317, 318, 320, and 321 Data Sheets / Record Target Thrust Values J l

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Safety Injection Valves In-Service Testing, Surveillance.e Test l ST-ISI-SI November 1986, for M0s HCV-311, 312, 314, 315, 317, 318, l 320, and 321

Preliminary Root CL 1 Investigation of Cracks Found in Motor Operator Housings of Safety-Related Valves - Draft, January 1989 The NRC inspector determined that the above documentation appeared ,

adequate to demonstrate that OPPD had identified all overthrust conditions on the HPSI M0s and had proceeded with the appropriate corrective actio However, October 1988, the licensee reported to the NRC that cracks were l identified in the gear housing of the as-found overthrust condition M0s and replacements were ordered and installed. The cracks in these M0 gear housings suggests an overstress condition could have been caused by 1) operation of the M0 near the limiting conditions of torque thrust; ;

2)torqueswitchadjustmentscausingoverlimitingthrustconditions; '

3) Marfak grease migration to the belleville spring pack and hardening causing over limiting thrust conditions (prior to 1985); and (4) Nebula '

EP-0 grease to the belleville spring pack with an inadequate designed grease relief which promugated a hydraulic lock and a consequential over limiting thrust conditio A final root cause analysis (metallurgical examination) scheduled by 0 PPD for completion by end of August 1989, should fully address and document the applicability of the as-found overthrust condition M0s, to all safety-related SMB-00 MOs used at FCS. It should also address increased preventive maintenance requirements necessary to ensure all other safety-related SMB-00 M0s are not impacting expected lif NRC Inspection Report 50-285/89-05(0penItem 285/8836-03) identifies the M0 overstress issue as open pending the completion of OPPDs final doenmentation of a final root cause analysis, and further confirmed reasons for M0 gear housing crackin . Instrument Calibration (56700)

To ascertain whether the licensee was implementing an instrumentation calibration program that was in conformance with the license requirements and commitments, the NRC inspector evaluated the calibration program in accordance with Inspection Procedure 56700. The NRC inspector reviewed procedures used to perform instrument tests and the records of previously completed tests. This review included FCS Standing Order No. M-26 Revision 15, dated August 25,1988, " Calibration Procedures," to evaluate the general requirements for all instrument tests and calibration .1 Calibrations Specified by TS Calibrations required by TS are controlled as part of FCS Standing Order No. G-23, Revision 28, dated December 28, 1988, " Surveillance Test

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Program." The inspection determined that procedures for calibraflon of plant installed instrumentation and control (18C) devices, specified by TS, are being implemented in accordance with the program administrative ;

controls, as prescribed by the FCS Updated Safety Analysis Report (USAR), 1 Section 7.0, and related commitments to Regulatory Guides and Standard The NRC inspector reviewed surveillance test procedures with regard to instrument device tests listed in TS Table 3-1. The surveillance test I

, procedures reviewed are listed as follows:

TS Table / SurveillanceRevision Description 4

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Item Test Procedure N / ST-RPS-3 43 Reactor Coolant Flow ]

and / ST-RPS-5 14 High Pressurizer Pressure and Channels l

3-1/ ST-RPS-6 12 Steam Generator Level .

f and Channels 3-1/ ST-RPS-7 19 Steam Generator Pressure and Channels The review of the above surveillance procedures included (1) that approved procedures were used; (2) acceptance criteria was met; and (3) an examination for technical conten i No violations or deviations were identifie .2 Calibrations Not Specified by TS (56700)

The programmatic controls for calibration of installed 180 devices used at FCS for applications not addressed in the TS, are part of the FCS Preventive Maintenance (PM) Program. The schedule of calibration and verification for these installed 1&C devices is outlined FCS Standing Order M-2, Revision 15. " Preventive Maintenance Program." Conditions required to perform calibrations on plant installed instrument devices are further defined in Standing Order M-26, Revision 1 OPPD has accomplished an engineering review of installed instrument devices to determine their requirements with regard to PM calibration activities at FCS. OPPD has established an approved and active PM Forecasting Re Procedure (CP) port and Tasking developed Report to controlaand Repetitive Maintenance accomplish the requiredCalibration instrument device calibration PM activitie ,

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Safety Injection Valves In-Service' Testing,~ Surve111ance Tests. .

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i ST-ISI-SI November.1986,'for M0s HCV-311, 312,z314, 315, 317, 318, 320, and 321

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. Preliminary Root Cause Investigation of Cracks.Found in Motor- ,

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l Operator Housings:of. Safety-Related Valves - Draft, January 1989:  !

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L, The NRC inspector determined that' the above documentation appeared '

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, a cuatelto ' demonstrate that' 0 PPD had identified all: overthrust conditions-

on we HPSI:MOs and had proceeded with the appropriate corrective actio .

However, October 1988,.the licensee. reported to the NRC that cracks wer identified in the gear housing ofo the as-found overthrust condition MOs-and replacements were ordered and installed. The cracks inlthese M0 gear housings suggests an overstress condition could have been caused by- j (1) operation of the MO nearithe limiting conditions'of torque thrust; ,

'j (2)torqueswitchadjustmentscausingoverlimiting;thrustconditions; (3) Marfak grease migration to the believille spring pack.and hardening causing over limiting thrust conditions (prior to-1985); and.(4) Nebula- u EP-0 grece to the believille; spring l pack with anlinadeqeate designed 1 grease relief which promugated a hydraulic lock and a consequential .over limiting thrust conditio '

A final root cause analysis (metallurgical' examination) scheduled.by 0 PPD I for completion by end of August .1989, should fully. address and document i the applicability of the as-found overthrust condition MOs, to.all- '

safety-related SMB-00 M0s used at FCS. It should also address increased preventive maintenance requirements necessary to ensure all'other u i safety-related SMB-00.M0s are not impacting expected lif !

l NRC Inspection Report 50-285/89-05(0penItem 285/8836-03)' idenkifiesthe M0 overstress issue as open pending the' completion of OPPDs final 1 documentation of a final root cause analysis, and further confirmed 1 reasons for.MO gear ho~, sing crackin j

! Instrument Calibration (56700)- 1 i

To ascertain whether the licensee was. implementing an instrumentation-  :

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calibration program that was'in conformance with the license requirements' i and commitments, the NRC inspector evaluated the calibration program in accordance with Inspection Procedure 56700. The NRC inspector reviewed procedures used to perform instrument tests and'the records of previously-

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l completed. tests. -This review included ~FCS-Standing' Order No. M-26, Revision 15, dated August ~25, 1988, " Calibration Procedures," to evaluate ;

l the general requirements for all instrument tests and calibration '

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3.1 Calibrations Specified by TS ~ '

Calibrations required by TS 'are controlled as partfof FCS Standing Order l No G-23 Revision 28, dated December 28, 1988, " Surveillance Test

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Program.!' The inspection determined that procedures for calibration of i plant installed instrumentation and control (I&C) devices, specified by  ;

TS, are being implemented in accordance with the program administrative 1 controls, as prescr; bed by the FCS Updated Safety < Analysis Report (USAR), l Section 7.0, and related' commitments to Regulatory Guides.and Standard )

The NRC inspector reviewed surveillance test procedures with regard to instrument device! tests listed in TS Table 3-1. The surveillance test '

procedures reviewed are listed as follows:

TS Table / Surve111anceRevision . Description Item Test Procedure N / ST-RPS-3 43- Reactor Coolant Flow and ,

3-1/ ST-RPS-5 14' High Pressurizer Pressure' ];

and Channels I

3-1/ ST-RPS-6 12 Steam Generator Level J and Channels 3-1/ ST-RPS-7 19 Steam Generator Pressure and Channels ,

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The review of the above surveillance procedures included (1) that approved procedures were used; (2) acceptance criteria was met; and (3) an examination for technical conten q No violations or deviations were identifie .2 Calibrations Not Specified by TS (56700) ,

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The programmatic controls for calibration of installed 18C devices used at  :

- FCS for applications not. addressed in the TS, are part of'the FCS Preventive j l

Maintenance (PM) Program. The schedule of calibration and verification l for these installed I&C devices is outlined FCS Standing Order M-2, Revision 15. " Preventive Maintenance Program." -Conditions required to

_ perform calibrations on plant installed instrument devices are further

. defined in Standing Order.M-26 Revision 1 :

OPPD has accomplished an engineering review of installed instrument -

devices to determine their requirements with regard to PM calibration activities at FCS. OPPD has established an approved and active PM '

Forecasting Re Procedure (CP) port and Tasking developed Report to controla and Repetitive Maintenance accomplish the required Calibration instrument device calibration PM activitie !

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The NRC inspector reviewed the licensee's implementation of Procedures M-2 and M-26, to ascertain whether calibration of the selected instrument devices in the PM program were effectively being accomplished. The NRC inspector reviewed the licensee's Computer History and Maintenance Planning System (CHAMPS). The CHAMPS data base is used by OPPD to prioritize the scope and frequency of the required PM calibration activities. The NRC inspector sampled PM data packa due calibrations; (2)ges listed for reasons on deferrals the data /base for (1) backlog cancellations of. past

/ inactivations, if any; (3) approved criteria met; and (5) procedures available; technical conten and (4)PM The sample examination data package for acceptance review, were limited to instrument device calibrations performed by Instrument and Control / Electrical Maintenance Groups, and are listed below:

CP N Revision Description CP-981 4 Extraction Steam to Auxiliary Steam Flow CP-6287A-M 8 Hydrazine, Monitor A CP-573 1 Auxiliary Building Sump Room 23 Level CP-565 3 Sump Room 21 Level CP-566 2 Sump Rocm 22 Level CP-567 3 Sump Rocm 23 Level CP-714 4 Containment Cooling Unit Discharge Temperature, Ch 714 CP-715 3 Containment Cooling Unit Discharge Temperature, Ch 715 CP-716 4 Containment Cooling Unit Discharge Temperature, Ch 716 CP-717 3 Containment Cooling Unit Discharge Temperature, Ch 717 CP-596 5 Waste Concentrate Tank B Level CP-592 6 Waste Concentrate Tank A Level The NRC inspector determined that the PM data packages were complete; acceptance criteria had been met; the proper approved test procedures had i been used; and technical contents were acceptable. The NRC inspector determined that cancellations and deferments of calibrated instrument devices were not frequen No violations or deviations were identifie . .. .. _ - _ - _ _ _ _ _ _ _

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7 Exit Interview The NRC inspector met with members of the licensee's staff identified in paragraph 1 at the 'end'of the inspection. At this meeting, the NRC inspector sumarized the secpe of the inspection and the' findings. The licensee did not identify as proprietary any of the information provided to, or reviewed by, the NRC inspecto ;

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