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{{#Wiki_filter:\rIndiana'Achrga~PowerCompany~~080c'.663' | {{#Wiki_filter:\rIndiana'Achrga~PowerCompany~~080c'.663'Nl7lAMA | ||
Mr.A.B.DavisAEP:NRC: | NTCHIGANPOWERAEP:NRC:1125A | ||
DonaldC.CookNuclearPlantUnits1and2DocketNos.50-315and50-316LicenseNos.DPR-58andDPR-74NRCINSPECTION | |||
NOS.50-315/89031 | |||
AND50-316/89031: | |||
RESPONSETOVIOLATION | |||
U.S.NuclearRegulatory | |||
Commission | |||
Attn:DocumentControlDeskWashington, | |||
D.C.20555Attn:A.B.Davi.sAprilll,1990DearMr.Davis:ThisletterisinresponsetoMr.H.J.Miller'sletterdatedMarch1,1990,whichforwarded | |||
thereportonthespecialmaintenance | |||
teaminspection | |||
conducted | |||
byMr.Z.Falevitsandothersofyourstaff.Thisinspection | |||
wasconducted | |||
fromDecember4through8,andDecember18through22,1989,onactivities | |||
attheCookNuclearPlantassociated | |||
withthesupportandimplementation | |||
ofmaintenance | |||
toensurethatplantstructures, | |||
systemsandcomponents | |||
reliablyperformondemand.TheNoticeofViolation | |||
attachedtoMr.Miller'sletteridentified | |||
sixweaknesses | |||
andfourSeverityLevelIVviolations | |||
relatingtoourmaintenance | |||
program.Theweaknesses | |||
areaddressed | |||
inAttachment | |||
1tothisletter.Theviolations | |||
areaddressed | |||
inAttachment | |||
2tothisletter.A14-dayextension | |||
forourresponsewasgrantedonMarch15,1990'hisdocumenthasbeenpreparedfollowing | |||
Corporate | |||
procedures | |||
thatincorporate | |||
areasonable | |||
setofcontrolstoensureitsaccuracyandcompleteness | |||
priortosignature | |||
bytheundersigned. | |||
Sincerely, | |||
M.P.AlichVicePresident | |||
ldpAttachments | |||
~)g4QOCk&2 | |||
900411pggADQcKo>oog+~~~Ipp1/00 | |||
Mr.A.B.DavisAEP:NRC:1125A | |||
cc:D.H.Williams, | |||
Jr.A.A.Blind-BridgmanR.C.CallenG.CharnoffNRCResidentInspector | |||
-BridgmanNFEMSectionChief | |||
ATTACHMENT | |||
1TOAEP:NRC:1125A | |||
RESPONSETONRC-IDENTIFIED | |||
WEAKNESSES | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page1NRC-Identified | |||
Weakness(1)"Lackoforineffective | |||
actiontocorrectnumerousselfidentified | |||
maintenance | |||
problemsidentified | |||
inFebruary1988,manyofwhichwereidentified | |||
bytheteamduringthisinspection." | |||
ResponsetoWeakness(1)Corrective | |||
ActionsTakenAsaresultofthe1988Maintenance | |||
Self-Assessment | |||
Report,AEPSCcontracted | |||
IMPELLtoassistinidentifying | |||
andformulating | |||
appropriate | |||
corrective | |||
actionstoaddresstheself-identified | |||
deficiencies. | |||
Theresultsofthi,seffortareinadocumententitled, | |||
D.C.CookPlantPMProramUradeStrateDocument, | |||
datedNovember1988.Thisstudycontained | |||
astrategyforAEPtoaccomplish | |||
aplannedupgradeofthePreventive | |||
Maintenance | |||
(PM)ProgramattheCookNuclearPlant.Itidentified | |||
reasonable | |||
goalsandachievable | |||
objectives | |||
forthePMUpgradeProgrambasedonAEPSC/Cook | |||
NuclearPlantphilosophy, | |||
resources | |||
andcapabilities. | |||
Thespecificimplementation | |||
tasksandstrategic | |||
considerations | |||
werepresented | |||
forobtaining | |||
thedesiredupgraderesults.Thiseffort'ot | |||
onlyaddressed | |||
improvements | |||
inthePMProgramitself,butalsoexaminedrelatedorganization | |||
andautomation | |||
requirements | |||
tosupporttheimprovedPMProgram.Basedontheresultsofthisstudy,numerouscorrective | |||
actionswereinitiated | |||
inJanuary1989.Thefirstwastheinitiation | |||
ofareliability-centered | |||
maintenance | |||
(RCM)program.Thismajortaskhastwophases:analysisandimplementation. | |||
AEPSChasbeenworkingcloselywithGeneralPhysicsontheanalysisportionthatwillformthefoundation | |||
oftheRCMprogram.Thisworkincludes: | |||
definingsystemboundaries | |||
andfunctions | |||
identifying | |||
dominantfailuremodesdetermining | |||
criti.cal | |||
failuremodesandcriti.cal | |||
components | |||
identifying | |||
applicable | |||
andeffective | |||
preventive | |||
maintenance | |||
taskstopreventfailurescompleting | |||
analysisofselectedplantsystems | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page2Implementation | |||
oftheRCMProgrambeganinAugust1989withthedevelopment | |||
ofplantprocedures, | |||
identification | |||
ofsystemboundaries, | |||
andestablishment | |||
ofanRCMdatabase. | |||
Thefirstsyst:emanalysiswascompleted | |||
inFebruary1990onthefeedwater | |||
system.Analysisof22additional | |||
plantsystems/functional | |||
areaswilltakeplaceoverthenextthreeyears.Anotheroutgrowth | |||
oftheMaintenance | |||
Self-Assessment | |||
ReportandtheAEPSC/IMPELL | |||
studywasthedevelopment | |||
oftheSystemEngineerProgram.ThegoaloftheSystemEngineerProgramistoprovidetrainingtoenableindividuals | |||
toprovidetheengineering | |||
expertise | |||
requiredforsafe,efficient | |||
andreliableoperation | |||
ofsystemsforwhichtheyareresponsible. | |||
TheSystemEngineerdischarges | |||
thisresponsibility | |||
byperforming | |||
assignedtasks,andmaintaining | |||
cognizance | |||
ofallworkassociated | |||
withtheassignedsystem(s). | |||
Inaddition, | |||
AEPSCcontracted | |||
TENERASystemsandSoftwaretoprovideacomputerized | |||
maintenance | |||
management | |||
information | |||
system.Thissystem,referredtoastheNuclearPlantMaintenance | |||
Module(NPM)System,discussed | |||
inmoredetailinourresponsetoweakness(3),willallowplantstafftoinitiate, | |||
issue,prioritize | |||
andtrackallmaintenance | |||
workattheplant.Thissamesoftwareiscurrently | |||
beingusedatPacificGasandElectric's | |||
DiabloCanyon,andPublicServiceElectricandGas'sSalemandHopeCreekGenerating | |||
Stations. | |||
Inaddition, | |||
itwasrecentlychosenbyElectricite | |||
deFranceforuseinallfiftyofitsnuclearplants.Thesethreeprograms, | |||
RCM,SystemEngineerandNPM,arejustpartoftheactionsthatarebeingtakentorespondtotheSelf-Assessment. | |||
TheNovember1989reorganization | |||
ofCookNuclearPlant'smanagement | |||
isanotherimportant | |||
elementintheupgradeofourmaintenance | |||
program.Theintentoftheneworganization | |||
istoplaceemphasisonmaintenance, | |||
outages,andhuman'resources, | |||
Otheractions,whichhaveorarebeingtakenareasfollows:oAnAEPandCookNuclearPlantpolicyonmaintenance | |||
wasdeveloped | |||
andapprovedinDecember1989byAEPseniormanagement. | |||
Anadditional | |||
plant-specific | |||
maintenance | |||
policyestablished | |||
inaccordance | |||
withINPOguidelines | |||
isbeingdeveloped | |||
toclarifymaintenance | |||
philosophies | |||
andresponsibilities | |||
forallmaintenance | |||
groups | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page3oCorporate | |||
reviewshavebeenconducted, | |||
whichhaveresultedinimprovements | |||
beingmadetoshopareasusedbythemaintenance | |||
groupsoStaffingstudiesarebeingperformed, | |||
whichhavealreadyresultedinanincreaseinthenumberofengineers | |||
andradiation | |||
protection | |||
technicians | |||
onsite.oOtherprogramsofnotethataddressmaintenance | |||
self-assessment | |||
findingsincludethemaintenance | |||
procedure | |||
rewrite(SeeWeakness(6)),thelong-range | |||
planandtheoutageguideline | |||
development | |||
plan.(2)BenefitsToBeDerivedFromCorrective | |||
ActionsRCM,theSystemEngineerProgramandNPMwereinitiated | |||
toaddressmanyoftheMaintenance | |||
Self-Assessment's | |||
identified | |||
deficiencies. | |||
Whenallofoureffortshavebeencompletely | |||
implemented, | |||
eachofthemajorfindingsoftheselfassessment | |||
willhavebeenaddressed. | |||
,Asaresultofthesecorrective | |||
actions.weanticipate | |||
havingastateoftheartmaintenance | |||
programwhichwillresultinimprovedplantsafety,reliability | |||
andaccountability. | |||
(3)DateWhenBenefitsVillBeRealizedAspreviously | |||
stated,westartedtheRCMPrograminAugust1989.However,weanticipate | |||
thattheprogramwillnotbecompletely | |||
implemented | |||
forallthecriticalplantsystemsuntiltheendof1992.Aseachsystemisanalyzed, | |||
benefitswillberealizedsothatwhenthisprogramiscompleted | |||
wewillhaveafullyintegrated | |||
preventive | |||
maintenance | |||
program.TheSystemEngineerProgram,likeRCM,isstillintheearlystagesofimplementation. | |||
Adocumentwhichclearlydelineates | |||
theresponsibilities | |||
oftheengineers | |||
iscurrently | |||
inthefinalstagesofreviewandapproval. | |||
AEPSC'sacquisition | |||
ofTENERA'sNPMsystemwasapprovedinDecember1989.However,itwillnotbeinplaceandoperational | |||
untilAugust1990,whendatawillbeentered.Vewillbeconducting | |||
QAauditsorsurveillances | |||
toaccessthestatusandeffectiveness | |||
ofsomeofourcorrective | |||
actionsastheydevelop.Inaddition, | |||
theMaintenance | |||
Improvement | |||
Planwillreviewandresolve,asappropriate, | |||
theMaintenance | |||
Self-Assessment | |||
items'heImprovement | |||
Planincludesmilestones | |||
andabuilt-inmechanism | |||
thatrequiresregularre-evaluation. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page4Whilewearealreadyrealizing | |||
benefitsfromourefforts,wedonotanticipate | |||
thefullbenefitforseveralyears.Inordertoeffectively | |||
implement | |||
programsasencompassing | |||
andcomprehensive | |||
asthese,significant | |||
analysis, | |||
planningandcoordination | |||
areneeded.Asaresult,theirbenefitswillnotbefullyrealizeduntilmid1993. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page5NRC-Identified | |||
Weakness(2)"Anineffective | |||
preventive | |||
maintenance | |||
programthatresulted, | |||
forexample,infailuresof4KVcircuitbreakers" | |||
ResponsetoWeaknessWeconcurthatthePreventive | |||
Maintenance | |||
Programcanbeimprovedand,aspreviously | |||
discussed, | |||
wearetakingstepstodoso.However,CookNuclearPlant'savailability | |||
in1989isevidencethatthepresentpreventive | |||
maintenance | |||
programiseffective. | |||
During1989,CookNuclearPlantgenerated | |||
12millionnetMWHRS,themostsince1984.The69.3%availability | |||
forUnit1in1989contributed | |||
toanaverageavailability | |||
of79.4%since1985'lthoughUnit2overallavailability | |||
hasnotbeenashighduetosteamgenerator | |||
tubedegradatidn, | |||
its74.4%availability | |||
in1989wasthehighestsince1983.OnDecember8,the111-dayrecordforthelongestrunwithbothunitsoperating | |||
wasbroken.Thisrecordwasextendedto140dayswhenUnit2wasbroughtoff-lineforasurveillance | |||
outageonJanuary6,1990.Unit1ended1989withitslongestrunof175daysandcontinued | |||
operating | |||
untilMarch17,1990(aCookNuclearPlantrecordrunof251days)whentheunitwasbroughtofflineforaplannedsurveillance | |||
outage.Asdiscussed | |||
inourresponsetoNRCviolation | |||
(2)oftheinspection | |||
report,the4KVcircuitbreakersfailurewasdetectedduringpreventive | |||
maintenance | |||
testing.Asaresult,appropriate | |||
corrective | |||
actionwas.subsequently | |||
takenwhichresultedinimprovements | |||
toour4KVbreakers. | |||
Also,wenotifiedtheindustryoftheproblemviaaPart21report. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page6NRC-Identified | |||
Veakness(3)"Anextensive | |||
backlogofnon-outage | |||
corrective | |||
maintenance | |||
joborderspartlycausedbylackofintegrated | |||
planningandscheduling | |||
methodology." | |||
ResponsetoWeakness"Maintaining | |||
theCookNuclearPlantinvolvesthecompletion | |||
ofapproximately | |||
20,000JobOrdersannually. | |||
Therelativepriorities | |||
ofjobschangefrequently | |||
duetoanumberoffactors,theprimaryreasonbeingplantconditions. | |||
Managingtheinformation | |||
contained | |||
withinthebacklogofyet-to-be | |||
completed | |||
JobOrderscanbecriticaltoplantavailability | |||
andreliability. | |||
Theseeffortsarepresently | |||
hamperedbythelogistics | |||
ofpaperfilingsystemsandcomputertrackingsystemsthatlackneededflexibility | |||
inhardwareandsoftware. | |||
(1)Corrective | |||
ActionsTakenTheCookNuclearPlantInformation | |||
Management | |||
System(IMS)plan,approvedfordevelopment | |||
inFebruaryof1989identified | |||
ninecomputersystemmodulesthat,whencompleted, | |||
willformasingle,integrated | |||
information | |||
management | |||
system.Thisautomated | |||
information | |||
systemwillbeusedbybothplantsiteandcorporate | |||
personnel | |||
tosupportplantoperation | |||
andmaintenance. | |||
Itwillprovideforthescheduling | |||
andinitiation | |||
ofmaintenance | |||
tasksandsupporttheassignment | |||
ofresponsibilities | |||
andaccountabilities | |||
forthesetasks.Specifically, | |||
formaintenance, | |||
theNuclearPlantMaintenance | |||
Module(NPM)oftheCookNuclearPlant'sIMSplanwillallowplantstafftoinitiate, | |||
issue,prioritize, | |||
andtrackallmaintenance | |||
workattheplant.TheNPMmoduleoftheIMSplanwillalsomaintainahistoryofmaintenance | |||
work.Theprimaryobjectives | |||
oftheNPMmodulearetoimproveplantavailability | |||
andtooptimizetheuseofplantresources | |||
withtheoverallgoalofreducingplantmaintenance. | |||
TheNPMsystemisdesignedtoallowanyNPMusertoinitiateastructured | |||
requestthattheuserbelievesshouldbereviewedand,ifwarranted, | |||
actedupon.Thisactionrequestfeatureprovidesaprocessforscreening | |||
thoseactionsrequiring | |||
work,andwillserveasafocalpointforinitiating | |||
andtrackingJobOrders.Plantpersonnel | |||
willenterdataintotheNPMsystemdefiningthecomponent | |||
thatneedsworkandbrieflydescribing | |||
thatwork.Thesystemisdesignedtoeliminate | |||
allpaperinthisprocessexcepttheactualJobOrderitself. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page7ThereviewsthattakeplaceintheJobOrdersystemareperformed | |||
on-line.Thison-linecapability | |||
allowsforpendingJobOrderstobesortedinvariouswaysandthereviewing | |||
individuals | |||
have'mmediate | |||
accesstothisinformation. | |||
Oncereviewsareperformed | |||
theactualJobOrderscanbeprintedfortheworktobeperformed. | |||
OnceaJobOrderhasbeeninitiated, | |||
startingfromtheveryfirstentryintothesystemandnotjustfromthetimeitgetsprinted,theJobOrderprocessing | |||
systemcantrackthestatusoftheJobOrder.Thisisaccomplished | |||
throughtheuseofstatuscodefields.Someofthecodesrepresent | |||
situations | |||
suchaswaitingformaterials, | |||
orwaitingforapprovalofthereviews,orothertypesofconditions. | |||
Thisfeatureisveryhelpfulforplanningandscheduling | |||
themanyJobOrdersinthesystem.TheNPMsystemwillpermittheplantstafftoassignspecificJobOrders,attheactivitylevel,toascheduled | |||
date,crewandsupervisor. | |||
Uponcompletion'f | |||
thecrewassignments | |||
andconfirmation | |||
ofpermitrequirements, | |||
thesystemproducesasupervisory | |||
assignment | |||
reportandprintstheJobOrder.Thecompleted | |||
workpackageincludestheJobOrder,equipment | |||
descriptions, | |||
partslist,andtestingformsalongwithotherneededdocuments. | |||
OncetheworkrelatedtoaJobOrderhasbeencompleted | |||
andtested,theJobOrderisreviewedandclosedout,on-line.TheNPMsystemmaintains | |||
acompletehistoryofallcompleted | |||
andclosed-out | |||
JobOrders.ThisfeatureallowsforrapidaccesstoallhistoryonJobOrders.TheNPMsystempreventsaJobOrderfrombeingclosed-out | |||
untilallreviewsandtestshavebeencompleted. | |||
Znaddition, | |||
theNPMsystemwillbearepository | |||
forpreviousrepetitive | |||
tasks.Thisfunctioneliminates | |||
theneedforindividuals | |||
torecreateJobOrdersthatarerepetitive | |||
innature,TheNPMsystemwillautomatically | |||
generatetheJobOrders,,according | |||
totheappropriate | |||
duedates,orasdirectedbyaplanner.TheNPMsystemwillalsoprovideforcontinuous | |||
monitoring | |||
ofsurveillance | |||
testsandpreventive | |||
maintenance | |||
worktomeetregulatory | |||
orplantrequirements. | |||
Oncetherepetitive | |||
orpreventive | |||
maintenance | |||
JobOrdersarecreated,theyareavailable | |||
forreviewsandexecutions | |||
inthesamemannerasanyoftheotherJobOrders.ThissystemwillalsobeusedtodevelopJobOrdersforplannedoutagessuchasrefueling | |||
outages. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page8(2)BenefitsToBeDerivedFromCorrective | |||
ActionsThedataenteredintotheNPMsystem,andtheprocessing | |||
thatthesystemdoeswiththisdata,willeliminate | |||
themultiplemanualdataentrystepsofourpresentprocess.Eliminating | |||
redundant | |||
manualsystemsisofsignificance | |||
itself.However,moreimportantly | |||
aretheanticipated | |||
improvements | |||
inplantavailability | |||
andlaborproductivity. | |||
Alongwithimprovedabilitytoplanandscheduleworkcomesanincreased | |||
amountoftimeavailable | |||
formorecarefulconsideration | |||
ofotheraspectsoftheworktobeperformed, | |||
forexample,personnel | |||
safety.Improvements | |||
canbeexpectedandwillcertainly | |||
bestrivedfor.TheNPMsystemwillalsoidentifyandcoordinate | |||
maintenance | |||
onrelatedequipment | |||
andsystems,thusdecreasing | |||
downtimeoncomponents | |||
removedfromservice.Quickaccesstotheinformation | |||
intheNPMdatabasesmakesthesupervisors | |||
inboththeoperations | |||
andmaintenance | |||
areasmoreawareofJobOrderprogress. | |||
Itisanticipated | |||
thattheNPMsystemw'illhelpusrealizeourgoalofanon-outage | |||
corrective | |||
maintenance | |||
joborderbacklognotinexcessof90days.(3)DateWhenBenefitsWillBeAchievedWecurrently | |||
anticipate | |||
havingthecomputerized | |||
automated | |||
maintenance | |||
systeminplaceandoperational | |||
byAugust1990.Atthattime,datavalidation | |||
andloading,procedure | |||
changesandtrainingofpersonnel | |||
willbegin. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page9NRC-Identified | |||
Weakness(4)"Poormaterialcondition | |||
especially | |||
asevidenced | |||
bythehighnumberofoil,steamandwaterleaks."ResponsetoWeakness(1)Corrective | |||
ActionsTakenWhileitisAEPSC'spolicytokeepallofitsfacilities, | |||
ingoodmaterialcondition, | |||
werecognize | |||
theneedforimprovement | |||
inthisarea.Asaresult,themanagement | |||
oftheCookNuclearPlanthaslaunchedaconcerted | |||
efforttoimproveplantmaterialcondition. | |||
Thisisevidenced | |||
bytheallocation | |||
offundstosupportthefollowing | |||
physicalimprovements | |||
thatarecurrently | |||
takingplace:oAuxiliary | |||
buildingpaintingoContaminated | |||
equipment | |||
storageareaexpansion | |||
IoDecontamination | |||
arearedesignoImprovedlightingoInstallation | |||
of18personnel | |||
wholebodycontamination | |||
monitorsItisCookNuclearPlantpolicythatnoleakisconsidered | |||
acceptable. | |||
Consequently, | |||
duringthe1988/1989 | |||
refueling | |||
outageswerefurbished | |||
about1,780valvesandpackedthemwithChesterton | |||
packing.Abreakdown | |||
ofthiseffortisasfollows:Unit1Unit2TotalAuxiliary | |||
BuildingContainment | |||
TurbineHallMiscellaneous | |||
254130225211502807009255071250504Nevertheless, | |||
asubstantial | |||
numberofleaksstillexistintheauxiliary | |||
building, | |||
rangingfromsmalltracesofdriedboricacidtodripping. | |||
Theseleakshavebeenenteredintoacomputerdatabase,havebeenchalkeddown,andjobordershavebeenwritten.Theleaksarecurrently | |||
beingprioritized | |||
andeffortswillbemadetorepairthemduringthenextrefueling | |||
outage,ifnotbefore. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page10Theplantmanagerhasreaffirmed | |||
hiscommitment | |||
togoodplantmaterialcondition | |||
andpersonalaccountability | |||
bysendingamemorandum | |||
toeachemployee. | |||
Thiscommitment | |||
hasbeensupported | |||
bycontinued | |||
radiation | |||
workerawareness | |||
training, | |||
andoperatortrainingonventinganddraining. | |||
Inaddition, | |||
decontamination | |||
effortscontinue, | |||
whichhavealreadyreducedthecontaminated | |||
areafromapproximately | |||
45,000feetin1986tothecurrent25,000feet(excluding | |||
laydownareas).Ourgoalistoreducethesecontaminated | |||
areasto20,000squarefeetin1990and10,000squarefeetpriortotheoutagein1991.(2)BenefitsToBeDerivedfromCorrective | |||
ActionsTherearenumerousbenefitsgainedfromhavingtheplantingoodphysicalcondition, | |||
themostimportant | |||
ofthesebeingincreased | |||
plantsafetyandreliability. | |||
Arelatedbenefitisimprovedradiation | |||
protection | |||
andworkersafety.However,anotherimportant, | |||
butlessquantifiable | |||
benefitistheimprovement | |||
toworkermorale.(3)DateWhenBenefitsWillBeRealizedWhilemaintaining | |||
theplantingoodphysicalcondition | |||
isanongoingprocess,weanticipate | |||
majorimprovements | |||
withinthenextyear.Therefueling | |||
outagewillfacilitate | |||
therefurbishment | |||
ofvalises,aswellasotherrepairsandmodifications. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page11NRC-Identified | |||
Weakness(5)"Inadequate | |||
trending, | |||
rootcauseanalysisandactiontocorrect,forexample,numerousleakingsafetyreliefvalves."ResponsetoWeakness(1)Corrective | |||
ActionsTakenThisweaknessisbeingaddressed | |||
bythreeprograms: | |||
theNPMsystemwhichisdiscussed | |||
indetailinourresponsetoweaknesses | |||
(1)and(3),theSystemEngineerProgram,discussed | |||
inourresponsetoweakness(1),andtheRCMProgramdiscussed | |||
inourresponsetoweakness(1).(2)BenefitsToBeDerivedfromCorrective | |||
ActionsTheNPMsystemwillprovideforacompletecomponent | |||
history.Thecomponent | |||
historywillprovideachronological | |||
listingofwork,modifications | |||
orinspections | |||
thathavebeenperformed | |||
onaparticular | |||
component. | |||
Thisprocesscreatesanindexedhistorical | |||
recordforcomponents | |||
orfunctional | |||
equipment | |||
groupsandcatalogscompletion | |||
dates,failurecodes,as-foundandas-leftconditions, | |||
partsreplaced, | |||
testresults,etc.TheSystemEngineers | |||
areexpectedtoidentifyandtrendappropriate | |||
systemparameters, | |||
withthegoalofobtaining | |||
pertinent | |||
dataforsystemperformance | |||
andreliability | |||
monitoring. | |||
Theparameters | |||
trendedshallbeperiodically | |||
reviewedandapprovedtoallowtimelypreventive | |||
orcorrective | |||
actionstobeimplemented. | |||
Basedonthetrendeddata,theSystemEngineerisexpectedtorecognize | |||
significant | |||
system/component | |||
degradation | |||
orabnormaloperating | |||
conditions | |||
frombothahistorical | |||
basis,aswellascurrentstatus.TheSystemEngineermayrequirethesupportoftechnical | |||
expertstoanalyzespecificareasofconcernandwillworkcloselywithourCorporate | |||
NuclearEngineering | |||
Divisionengineers | |||
inthisregard.TheSystemEngineers | |||
areexpectedtoperformrootcauseanalysesonthesystemsassigned. | |||
Consequently, | |||
theSystemEngineers | |||
willbetrainedinrootcauseanalysis. | |||
Inaddition, | |||
theSystemEngineerisexpectedto:Evaluatesystem/component | |||
failureimpactonplantsafetyandunitpoweroperations | |||
Prepareandperformspecialsystem/component | |||
performance | |||
tests. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page12TheRCMProgramwt.llcontribute | |||
toresolving | |||
thisissuebyidentifying | |||
dominantfailuremodesandcriticalcomponents. | |||
(3)DateWhenBenefitsWillBeRealizedAspreviously | |||
stated,weexpecttheNPMsystemtobeinplaceandoperational | |||
inAugust1990.Atthattime,personnel | |||
traininganddataloadingwillbegin.Severalsystemengineers | |||
havebeenassignedatCookNuclearPlantandbenefitshavealreadybeenrealizedfromthisprogram.Aneffortiscurrently | |||
beingmadetorecruitSystemEngineers. | |||
However,weanticipate | |||
itwilltakeatleastayearbeforetheprogramisfullystaffed. | |||
Attachment | |||
1toAEP:NRC:1125A | |||
Page13NRC-Identified | |||
Weakness(6)"Inseveralinstances | |||
procedures | |||
werenotfollowed, | |||
werepoorordidnotexistespecially | |||
inthebalanceofplantarea."ResponsetoWeakness(1)Corrective | |||
ActionsTakenKeytothesafeandefficient | |||
operation | |||
ofanynuclearpowerplantisstrictadherence | |||
toprocedures. | |||
Assuch,employees | |||
areshownduringtheNuclearGeneralEmployeeTraining(NGET)classes,avideotape | |||
ofDavidWilliams, | |||
Jr.,SeniorExecutive | |||
V.P.,Engineering | |||
andConstruction, | |||
mandating | |||
theadherence | |||
toprocedures. | |||
ItisAEPSC'slong-standing | |||
policythatfailuretofollowprocedures | |||
willresultindisciplinary | |||
action.Inorderforthispolicytohaveanybenefit,well-written | |||
andaccurateprocedures | |||
mustbeinplace.Consequently, | |||
AEPSCispurchasing | |||
PRONETandtheservicesofconsultant | |||
procedure | |||
writerstoupgradeorwrite690maintenance | |||
procedures | |||
(268maintenance, | |||
422I&C).Criticalbalanceofplantcomponents | |||
willbeaddressed | |||
astheyariseintheRCMprogram.TheMaintenance | |||
Improvement | |||
Planprovidesguidancethatclearlydefineswhatprocedure | |||
compliance | |||
is.Inaddition, | |||
aprocedure | |||
writer'/user's | |||
guidewilladdressthecircumstances | |||
forchangingaprocedure | |||
toensureprocedural | |||
compliance. | |||
(2)BenefitsToBeDerivedfromCorrective | |||
ActionsPRONETisastateoftheartcomputersystemthatintegrates | |||
writer'sguidelines, | |||
wordprocessing, | |||
graphicsanddatabasefunctions | |||
intoacentralized | |||
procedure | |||
management | |||
system.Development, | |||
commitment, | |||
scheduling | |||
andreporting | |||
functions | |||
willbecontrolled | |||
bythismenu-driven | |||
network.Thisintegrated | |||
approachwillresultinaprogramthatreducesdevelopment | |||
timeandprovidesefficient | |||
long-term | |||
procedure | |||
maintenance | |||
andcommitment/reference | |||
tracking. | |||
(3)DateWhenBenefitsWillBeRealizedAlthoughaconsultant | |||
willtrainplantstaffontheuseofPRONET,thebulkoftheprocedure | |||
upgradeworkwillbeperformed | |||
byconsultant | |||
personnel. | |||
Byusingcontractworkerswewillnotimpacttheplantstaff.Iftheexistingstaffwereused,itisanticipated | |||
thattheeffortwouldtakefourtofiveyears.Thisisconsidered | |||
tobeanunacceptable | |||
timeframeforthiswork.Byusingcontractworkers,wewillobtainprofessionally | |||
preparedprocedures | |||
inareasonable | |||
timeframe.Theeffortisscheduled | |||
tobecompleted | |||
byDecember1991. | |||
ATTACHMENT | |||
2TOAEP:NRC:1125A | |||
RESPONSETONRC-IDENTIFIED | |||
VIOLATIONS | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page1NRCViolation | |||
1"10CFR50,AppendixB,Criterion | |||
V,asimplemented | |||
bySection1.7.5oftheDonaldC.CookNuclearPlantOperational | |||
QualityAssurance | |||
Programrequiresthatactivities | |||
relatedtoqualitybeprescribed | |||
bydocumented | |||
instructions, | |||
procedures, | |||
anddrawings, | |||
thatthoseactivities | |||
beaccomplished | |||
inaccordance | |||
withthoseinstructions, | |||
procedures | |||
anddrawings, | |||
andthatinstructions, | |||
procedures | |||
ordrawingsincludeappropriate | |||
quantitative | |||
orqualitative | |||
acceptance | |||
criteriafordetermining | |||
thatimportant | |||
activt,ties | |||
havebeensatisfactorily | |||
accomplished. | |||
a~Procedure | |||
PMI-2290, | |||
"JobOrders,"Revision8,requiredinSections4.4.8and4.4.8.3thatuponcompletion | |||
ofthephysicalwork,thejobordertagsberemovedanddiscarded. | |||
Contrarytotheabo~e,tags15119,029643,B012209,B016950,B016832,andB017240werenotremovedalthoughthejoborderswerecancelled | |||
orcompleted. | |||
Asaresult,statusofequipment | |||
condi.tion | |||
remainedindeterminate | |||
(315/89031-01A; | |||
316/89031-01A) | |||
~b.RequestForChange12-2180requiredinstallation | |||
of200%overloadmotorprotection | |||
andthatthethermaloverloadbesetatthelowtripcurrentrating.Contrarytotheabove,onDecember19,1989,theinspectors | |||
observedthatthethermaloverloadheaterassociated | |||
withresidualheatremovalloopisolation | |||
motor-operated | |||
valveICM-111wassetatthehightripcurrentrating.Numerousadditional | |||
thermaloverloads | |||
inthedieselgenerator | |||
motorcontrolcenterwerealsoobservedtobethewrongsizeorsetatthewrongcurrentrating,whichwillresultinpremature | |||
removalofoperating | |||
voltagefromthemotors(315/89031-01B; | |||
316/89031-01B) | |||
~c~Procedure | |||
PMI-2030, | |||
"Document | |||
Control," | |||
Revision10,failedtoincluderequirements | |||
fortheMasterDrawingIndexestobereviewedbyintendedusersforthelatestasbuiltdrawingslocatedintheplantmasterfile.Consequently, | |||
drawingsissuedbythedocumentcontrolcenterforfieldverifications | |||
werenotthelatestasbuiltdrawingsorrevisions | |||
(315/89031-01C; | |||
316/89031/01C). | |||
The"PumpOperator's | |||
Data"manualandthevendormanualfor'heAuxiliary | |||
Feedwater | |||
(AFV)pumprequiredthatthepumppackingbeadjustedwhilethepumpisoperating. | |||
Contrarytotheabove,thisrequirement | |||
wasnotincorporated | |||
intotheAFVmaintenance | |||
procdures | |||
[sic).Althoughnoproblemswerenoted,inadequate | |||
attention | |||
tothisrequirement | |||
couldresultinrotorseizure,scoredshaftsleeves,orburnedpacking(315/89031-01D; | |||
316/89031-01D). | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page2Procedure | |||
12THP6030IMP.014"Protective | |||
RelayCalibration", | |||
Revision8,Step8.1.2-2specified | |||
thatblackelectrical | |||
tapebeusedwhencleaningthediskanddragmagnetmechanism | |||
onTimeOvercurrent | |||
(IAC)relays.Contrarytotheabove,onDecember5,1989,atechnician | |||
wasobservedusinganunusedcalibration | |||
stickertocleanthe2ABEDGTimeOvercurrent | |||
testrelay.Asaresult,cleanliness | |||
ofthecontactswasquestionable | |||
(315/89031-01E; | |||
316/89031-01E). | |||
f.Procedure | |||
PMI-2010"PlantManagerandDepartment | |||
HeadInstructions, | |||
Procedures | |||
andIndex,"Revision17,PolicyStatement | |||
3.1,Section3requiredthat"doubleasterisked" | |||
procedures | |||
forplantactivities | |||
be"in-hand" | |||
whenimplementing | |||
theprocedure. | |||
Contrarytotheabove,onDecember6,1989,theinspector | |||
observedanoperatorrackin"2A"TrainReactorTripBypassBreakerwithouthaving"inhand"doubleasterisked | |||
procedure | |||
~12-OHP4021.082.018 | |||
"RackingInandOutReactorTrip,ReactorTripBypassandMGSetOutputBreakers," | |||
Revision2.Eventhoughnoadverseaffectswerenoted,inthepastundersimilarcircumstances, | |||
areactortripoccurred(315/89031-01F; | |||
316/89031-01F). | |||
Procedure | |||
PMI-2010, | |||
"PlantManagerandDepartment | |||
HeadInstructions, | |||
Procedures | |||
andIndex,"Revision17,requiresinSection3.14.1thatalleffective | |||
instructions | |||
andprocedures | |||
bereviewednolessfrequentthanonceeverytwoyears.Contrarytotheabove,maintenance | |||
procedure | |||
MHI2070,MHI7090,PMI4050,12THP6030IMP~071,and12THPIMP.062werenotreviewedinthelasttwoyears.Asaresult,theprocedures | |||
werenotupdatedtoreflectfeedbackandchangestopreventive | |||
maintenance | |||
activities | |||
(315/89031-01G; | |||
316/89031-1G)." | |||
ResponsetoViolation | |||
laPlantprocedure | |||
PMI-2290requiresthattagsplacedatornearequipment | |||
needingrepairberemovedwhentheitemisrepairedoriftheJobOrderiscancelled. | |||
Asnotedinthetext,sixJobOrdertagswerefoundintheplantforworkthathadbeencancelled | |||
orcompleted | |||
whichconstitutes | |||
failuretofollowprocedure. | |||
Theconclusion | |||
madeinInspection | |||
Report89031wasthatequipment | |||
statuswas"indeterminate." | |||
WhilethepresenceofJobOrdertagswascontrarytotherequirements | |||
ofPMI-2290, | |||
thestatusofequipment/components | |||
involvedwouldnotbeaffected. | |||
Theinformation | |||
placedonatagidentifies | |||
topersonnel | |||
1)thataJobOrderhasbeenwrittenforrepairwithnumbernoted,2)thenatureofrepairs/adjustments | |||
requiredasdetermined | |||
bythepersoninitiating | |||
theJobOrderand3)helpslocatethespecificcomponent. | |||
Byitself,aJobOrdertaghasnoimpactonsystemorequipment | |||
operability, | |||
does | |||
Attachment | |||
2toAEP:NRC.:1125A | |||
Page3notindicatethatequipment | |||
hasbeentaggedout,anddoesnotdirectanyotheractivityinvolving | |||
theequipment. | |||
Othersystemssuchastheclearance | |||
permitsystemlogsandthedeficiency | |||
logsindicatetheequipment | |||
status.(1)Corrective | |||
ActionTakenandResultsAchievedJobOrdertagsidentified | |||
duringtheinspection | |||
weresubsequently | |||
removedtoachievecompliance | |||
withapplicable | |||
sectionsofPMI-2290. | |||
(2)Corrective | |||
ActionTakenToAvoidFurtherViolation | |||
ThePlantManagerwilli.ssueamemoonprocedural | |||
compliance | |||
toensurethatallpersonnel | |||
arefullyawareofthemeaningofcompliance, | |||
consequences | |||
offailureandwhatactionstotake~whenaprocedure | |||
cannotbefollowedaswritten.TheMaintenance | |||
Improvement | |||
Planincludesissuanceofadepartment | |||
policyonprocedure | |||
compliance. | |||
Includedwillbeguidanceonthemonitoring | |||
oftheeffectiveness | |||
ofprocedure | |||
compliance. | |||
Alsoaprocedure | |||
writer'/user's | |||
guidewilladdressthecircumstances | |||
forchangingaprocedure | |||
toensureprocedural | |||
compliance. | |||
(3)DateWhenFullComlianceWillBeAchievedThefinaldraftofthepolicywillbeissuedonJuly15,1990.Guidanceontheeffectiveness | |||
monitoring | |||
willbeissuedonAugust15,1990.ThePlantManager's | |||
memowillbeissuedonMay1,1990.ResponsetoViolation | |||
lbTheNoticeofViolation | |||
identified | |||
thatthermaloverloads | |||
intheplanthadbeeninstalled | |||
atanincorrect | |||
tripcurrentrating.Asaresultoftheinspection, | |||
plantpersonnel | |||
investigated | |||
theproblemandaddressed | |||
itinProblemReport90-81.(1)Corrective | |||
ActionTakenandResultsAchievedTheimproperpositioning | |||
and/ormis-sizing | |||
oftheoverloadheatersresultedfromerrorsmadeduringinitialinstallations. | |||
Twentyoverloads | |||
wereinspected | |||
andevaluated | |||
byplantandAEPSCengineers. | |||
Elevenwerefoundtob'ecorrect.Onewasfoundonabreakerforaresistive | |||
heaterwhereoverloadprotection | |||
wasnotconsidered | |||
criticalasmoldedcasecircuitbreakersprotection | |||
wasprovided. | |||
Onfourbreakers(including | |||
ICM-111)theas-foundheatersizeagreedwiththecalculated, | |||
butarrowpositiondidnotagree.Fullloadampswasatthedividingpointforselecting | |||
upordownposi.tion. | |||
Slightchangesinmotorprotection | |||
resultedbutdidnotaffecttheoperability | |||
ofload.FourfeedersonBOPwerefoundtobemis-sized. | |||
Ofthosefour | |||
Attachment | |||
2toAEP:NRC:1125A | |||
-Page4onewasmis-sized | |||
toadegreethatreplacement | |||
wasneededtoensureadequateprotection. | |||
Ofthethreeotheroverloadheaters,thoughimproperly | |||
set,wouldhaveprovidedthermaloverloadprotection | |||
forequipment. | |||
JobOrderstocorrectthesesettingsbyOctober30,1990,havebeenwritten.(2)Corrective | |||
ActionTakenToAvoidFurtherViolation | |||
Inthecourseoftheplant'sinvestigation | |||
itwasdetermined | |||
thatthemis-sizing | |||
and/ormispositioning | |||
ofthethermaloverloads | |||
hadoccurredduringinitialinstallation | |||
in1977and1978.Lackingvendorinformation, | |||
calculations | |||
weremostlikelydeveloped | |||
byplantpersonnel | |||
forpositions/sizes | |||
whichinsomeofthecases,provedincorrect. | |||
Thedesignchangeprocesshasevolvedsincethattimetoalevelthatreasonably | |||
ensuresthatrepetition | |||
ofasimilarcondition | |||
willnotoccur.Specifically, | |||
generalprocedures | |||
nowrequirethatdesigncalculations | |||
beverifiedanddocumented | |||
byqualified | |||
personnel. | |||
(3)DateWhenFullComlianceWillBeAchievedBasedontheengineering | |||
evaluation | |||
completed | |||
January15,'990,thedeficiencies | |||
inthethermaloverloadheatersettingswouldnothaveaffectedtheoperability | |||
oftheICM-111breaker.Otherdeficiencies | |||
didnotdegradethethermaloverloadprotection | |||
oftheequipment | |||
breakers. | |||
Currentprocedures/practices | |||
shouldpreventrecurrence | |||
ofthisproblem.ResponsetoViolation | |||
lcInthecourseoftheinspection | |||
itwasfoundthataplantinstruction | |||
utilizedfordocumentcontrol(drawings) | |||
contained | |||
noprovision | |||
mandating | |||
thattheuseroftheindexverifythatitwasthemostrecentupdate.Weconcurwiththeinspector's | |||
conclusion | |||
thataninstruction | |||
tousersoftheMasterDrawingIndextoensurethatitreferences | |||
up-to-date | |||
as-builtdrawingsshouldbeincludedinprocedures. | |||
(1)Corrective | |||
ActionTakenandResultsAchievedAsaresultoftheinspection, | |||
PMI-2030, | |||
"Document | |||
Control," | |||
wasrevisedtoinstructaMasterDataIndexusertoensurethatitreflectsthelatestas-builtdrawingslocatedintheplant'smasterfile.(2)Corrective | |||
ActionTakenToAvoidFurtherViolation | |||
Revision11toPMI-2030isbeingroutedforapprovalfromplantmanagement. | |||
Therevisionaddresses | |||
theinspector's | |||
concernnotedintheNoticeofViolation. | |||
IAttachment | |||
2toAEP:NRC:1125A | |||
Page5(3)DateWhenFullComlieneeWillBeAchievedTherevisedversionofPMI-2030willbeeffective | |||
byMay1,1990.ResponsetoViolation | |||
ldProcedural | |||
revisiontoincorporate | |||
adirection | |||
torunapumpinordertoproperlyadjustpackingisnotviewedasnecessary. | |||
Personnel | |||
performing | |||
packingadjustments | |||
meettherequirements | |||
ofANSIStandardN18-1(4.5.3).Consistent | |||
withthatstandard, | |||
maintenance | |||
personnel | |||
receiveformaltraininginsubjectsassociated | |||
withtheirposition. | |||
Includedintheplant'strainingisacourseonpumpsthatdirectlyreferences | |||
thecorrectmethodology | |||
foradjusting | |||
thepackingonpumps.Thisteachesmaintenance | |||
personnel | |||
thatadjustments | |||
willonlybemadetopackingwhenthepumpisoperating. | |||
AsrequiredbyANSIStandardN18-7,Section4.1(2),plantprocedures | |||
aredeveloped | |||
withtheobjective | |||
ofproviding | |||
adequateinformation | |||
topersonnel | |||
involvedinagiventaskconsidering | |||
theskilltheyareprovidedthroughthetrainingprogram.(1)Corrective | |||
ActionTakenandResultsAchievedThosepersonswhowouldbeinvolvedinpumppackingworkarehiredandtrainedconsistent | |||
withANSIN18-1.(2)Corrective | |||
ActionTakentoAvoidFurtherViolation | |||
Thehiringpractices | |||
andtrainingprogramshaveprovenadequatetopreventproblemsduetopumppacking(3)DateWhenFullComlianceWillBeAchievedNoviolation | |||
occurredaspractices | |||
areinaccordance | |||
withN18-1andpersonnel | |||
arefullyqualified. | |||
ResponsetoViolation | |||
leWhiletheintentofStep8.1.2-2ofmaintenance | |||
procedure | |||
12THP6030.IMP.014 | |||
wastoensurethattechnicians | |||
performing | |||
cleaningwouldutilizetapeorsimilaradhesive-backed | |||
material. | |||
Blackelectrical | |||
tape,wasspecified | |||
becauseitisacommonlyavailable | |||
item.However,useofacalibration | |||
stickerdid-constitute | |||
aviolation | |||
oftheprocedure | |||
aswritten.(1)Corrective | |||
ActionTakenandResultsAchievedMaintenance | |||
supervision | |||
reviewedtheneteffectofutilizing | |||
thestickerinthecourseofcleaninganddetermined | |||
thatsatisfactory | |||
resultswereobtained. | |||
Nore-cleaning | |||
wasdeemed | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page6necessary. | |||
12THP6030.IMP.014 | |||
hadbeenrevisedviaachangesheetinitiated | |||
April2,1990,toremovereference | |||
toblackelectrical | |||
tape.(2)Corrective | |||
ActionTakenToAvoidFurtherViolation | |||
ThePlantManagerwillissueamemoonprocedural | |||
compliance | |||
toensurethatallpersonnel | |||
arefullyawareofthemeaningofcompliance, | |||
consequences | |||
offailureandwhatactionstotakewhenaprocedure | |||
cannotbefollowedaswritten.TheMaintenance | |||
Improvement | |||
Planincludesissuanceofadepartment | |||
policyonprocedure | |||
compliance. | |||
Includedwillbeguidanceonthemonitoring | |||
oftheeffectiveness | |||
ofprocedure | |||
compliance. | |||
Alsoaprocedure | |||
writer'/user's | |||
guidewilladdressthecircumstances | |||
forchangingaprocedure | |||
toensureprocedural | |||
compliance. | |||
(3)DateWhenFullComlieneeWillBeAchievedThefinaldraftofthepolicywillbeissuedonJuly15,1990.Guidanceontheeffectiveness | |||
monitoring | |||
willbeissuedonAugust15,1990.ThePlantManager's | |||
memowillbeissuedonMay1,1990.ResponsetoViolation | |||
lf(1)Corrective | |||
ActionTakenandResultsAchievedTheAuxiliary | |||
Equipment | |||
Operator(AEO)involvedinthiseventhadreceivedtrainingontheoperation | |||
ofreactortripbreakersandtheexistence | |||
oftheprocedure | |||
priortothisevent.TheAEO,however,overlooked | |||
thereactortripbreakerprocedure | |||
wasrequiredtobe"inhand"wheneverperforming | |||
rackingoperations. | |||
Althoughtherackingevolution | |||
wasdoneinaccordance | |||
withthe.procedure | |||
requirements, | |||
thiseventwasaviolation | |||
becausetherequirement | |||
tohavetheprocedure | |||
"inhand"wasnotsatisfied. | |||
Amemorandum | |||
wasissuedtoOperations | |||
personnel | |||
onJanuary19,1990,toremindthemofthe"inhand"requirement | |||
forthereactortripbreakerprocedure. | |||
(2)Corrective | |||
ActionToBeTakenToAvoidFurtherViolation | |||
Theroutinesurveillance | |||
procedures | |||
forreactortripbreakertestingwererevisedonDecember13,1989,toreference | |||
therequirement | |||
forhavingthereactortripbreakerrackingprocedure | |||
"inhand"fortherackingevolutions. | |||
Thestartupsurveillance | |||
procedures, | |||
whichrequirerackingofthereactortripbreakers, | |||
willberevisedbyJune4,1990,toreference | |||
therequirement | |||
forhavingthereactortripbreakerprocedure | |||
"inhand." | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page7Duringtheconcluded, | |||
procedures | |||
Therefore, | |||
pasttwoyears,QAaudits/surveillances | |||
haveexceptfora"fewisolatedcases,"doubleasterisked | |||
haveinfactbeen"inhand"whenrequired. | |||
nogenericprogrammatic | |||
problemexists.(3)DateWhenFullComlianceWillBeAchievedFullcompliance | |||
wasachievedonDecember6,1989,whenthe'involved | |||
AEOwasreinstructed | |||
ofthe"inhand"procedural | |||
requirement. | |||
ResponsetoViolation | |||
lgFiveprocedures/instructions | |||
werecitedintheNoticeofViolation | |||
asnothavingbeenreviewedwithinthetwo-yearlimitestablished | |||
inplantprocedure | |||
PMI-2010. | |||
However,ineachcasethedocuments | |||
hadbeenreviewedanddocumentation | |||
tothateffectwasonfile.Uponrequestoneoftheinspectors | |||
wasprovidedwithbiannualreviewdocuments | |||
forIMP.071andIMP.062.Theinstruction | |||
doesnotrequireanapprovedrevisionwithintwo.years,onlyareviewpriortosuchrevision. | |||
Thisinformation | |||
maynothavebeenadequately | |||
communicated. | |||
(1)Corrective | |||
ActionTakenandResultsAchievedFurtherreviewoftheNoticeofViolation | |||
bytheplantidentified | |||
thatprocedures/instructions | |||
notedhadreceivedreviewasrequiredbyPMI-2010, | |||
Rev.17.(2)Corrective | |||
ActionTakentoAvoidFurtherViolation | |||
Trackingandreviewofprocedures | |||
ispresently | |||
adequate. | |||
(3)DateWhenFullComlianceWillBeAchievedNoviolation | |||
occurred. | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page8NRCViolation | |||
2"10CFR50,AppendixB,Criterion | |||
VIII,asimplemented | |||
bySection1.7.8oftheDonaldCDCookOperational | |||
QualityAssurance | |||
Programrequiredthatmeasuresbeestablished | |||
fortheidentification | |||
ofmaterials, | |||
partsandcomponents | |||
suchasbypartnumber,serialnumber,orotherappropriate | |||
meansontheitemorrecordstraceable | |||
totheitemthroughout | |||
fabrication, | |||
installation | |||
anduseoftheitem.""Contrary | |||
totheabove,identification | |||
ofmaterials | |||
andcomponents | |||
fortraceability | |||
wasnotaccomplished | |||
forcableextension | |||
portionsandaluminumsplicingsleevesforconnections | |||
toseveralsafety-related | |||
motorcontrolcentersinstalled | |||
undertheRequestForChange1482modification | |||
(315/89031-02; | |||
316/89031-02)." | |||
ResponsetoViolation | |||
2RFC-1482installed | |||
transition | |||
pieces(sleeves) | |||
tosplicecoppertoaluminumcablesinvariousmotorcontrolcenters.PerRFCinstructions, | |||
thetransition | |||
piecesweretobeinstalled | |||
inaccordance | |||
withEngineering | |||
DesignSpecification | |||
(EDS)607andEDS608'heinstallation | |||
tookplacebetweenJuneof1979andSeptember | |||
of1981whenthefinalsummarywasissued.Asearchofthecompleted | |||
RFCpackage(including | |||
installation | |||
joborders)andofthemicrofilm | |||
ofthecompleted | |||
joborderpackagesrevealednodocumentation | |||
oftheparts(sleeves) | |||
usedfortheinstallation. | |||
Individuals | |||
whowereinvolvedwiththeMaintenance | |||
Department | |||
atthattimestatedthatpersonnel | |||
wouldhaveinstalled | |||
thetransition | |||
piecespertheEDSasstatedintheRFC.Inadequate | |||
documentation | |||
ofmaterialinstalled | |||
byaJobOrderduringthedesignchangeprocesswastherootcauseofthisviolation. | |||
Additionally, | |||
therewereinadequate | |||
reviewofthecompleted | |||
jobordersandthedesignchangepackageuponcompletion. | |||
(1)Corrective | |||
ActionTakenandResultsAchievedTheinstallation | |||
tookplaceapproximately | |||
10yearsagoandwasperformed | |||
inaccordance | |||
withEDS608,whichwasreferenced | |||
intheRFCpackage.Actualapplication | |||
forthepasttenyearshasfunctionally | |||
demonstrated | |||
theadequacyofsubjectmaterials' | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page9(2)Corrective | |||
ActionTakenToAvoidFurtherViolation | |||
Currentprocurement/dedication | |||
practices | |||
ensureproperdocumentation | |||
isdeveloped | |||
todemonstrate | |||
controloverthesuitability | |||
ofmaterial, | |||
partsandcomponents. | |||
(3)DateWhenFullComlianceWillBeAchievedCurrentprocedures/practice's | |||
shouldpreventrecurrence | |||
ofthisproblemandensurefuturecompliance. | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page10NRCViolation | |||
3"10CFR50,AppendixB,Criterion | |||
XI,asimplemented | |||
bySection1.7.11oftheDonaldC.CookOperational | |||
QualityAssurance | |||
Programrequiredthatatestprogrambeestablished | |||
toassuretestingtodemonstrate | |||
thatsystemsandcomponents | |||
willperformsatisfactorily | |||
inserviceinaccordance | |||
withtestprocedures | |||
whichincorporate | |||
requirements | |||
andacceptance | |||
limitscontained | |||
inapplicable | |||
designdocuments, | |||
andthatadequatetestinstrumentation | |||
wasavailable | |||
andused.""Contrary | |||
totheabove,testinstruments | |||
werenotsensitive | |||
oraccurateenoughtoverifythecalibration | |||
oftheundervoltage | |||
relaysthatactuatetheEmergency | |||
DieselGenerators. | |||
Procedure | |||
2THP6030IMP.250,"4kVDieselStart,4kVESSBusUndervoltage | |||
RelayCalibration," | |||
Revision7,Section3.0,requiredtheuseofaWestinghouse | |||
typePA-161ACanolog[sic]voltmeter | |||
oritsequivalent | |||
withequalorbetteraccuracyandadequaterangetomeasurethedesiredparameters. | |||
However,thevoltmeter | |||
hadatolerance | |||
of+1.5voltsthatwasnotsufficiently | |||
accuratetomeasurethedesiredparameter | |||
of90.3to91.8voltsspecified | |||
inTechnical | |||
Specification | |||
3.3.2.Inaddition, | |||
thevoltmeter | |||
indicated | |||
tothenearestwholevoltanddidnothavedivisionmarkingsbetweenthenumbers.Technicians | |||
hadtointerpolate | |||
resultsandrecordvaluestothenearesttenthofavoltwhilethevoltmeter's | |||
dialindicator | |||
wasmovingintheincreasing | |||
ordecreasing | |||
direction. | |||
Furthermore, | |||
thetechnicians | |||
usedhandsignalstocommunicate | |||
themomenttheundervoltagerelayoperated. | |||
Basedontheinaccuracy | |||
andinsensitivity | |||
ofthevoltmeter, | |||
andpoortestingtechnique, | |||
resultsoftheundervoltage | |||
testwerenotconclusive | |||
(315/89031-03; | |||
316/89031-03)." | |||
ResponsetoViolation | |||
3Themeterusedwasfirstspecified | |||
intheoriginalprocedure | |||
developed | |||
beforeinitialplantstart-up. | |||
Thespecificreasonsforusingthismetercouldnotbedetermined. | |||
However,itisbelievedthatthiswasthelimitoftheavailable | |||
technology | |||
atthattime.Theonlyothermeteravailable | |||
wasabasicdigitaltype,whichcouldnotbeusedduetotheinherently | |||
slowresponseandupdatetime,causingagreateruncertainty | |||
ofspecificsetpointvaluethantheanalogmeter. | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page11(1)Corrective | |||
ActionsandResultsAchievedZ&CnowusestheFlukeModel45digitalmeterduringtestingofthe4KVdieselstartand4KVESSbusundervoltage | |||
relays.Recentdevelopments | |||
indigitalmeterswhichincludefasterresponsetimesandupdatetimesandminimum/maximum | |||
modifierfeatureshasmadetheiruseacceptable. | |||
Thedigitalmetercurrently | |||
beingusedhasanaccuracyof+0.3percent.Theprevioustestmethodprovidedacceptable | |||
results,basedontheas-foundvaluesonthefirstuseofthedigitalmetersbeinginspecification | |||
bycomparable | |||
percentages.'2) | |||
Corrective | |||
ActionsTakenToAvoidFurtherViolation | |||
Thecalibration | |||
procedures | |||
whichcurrently | |||
allowuseofeitheranalogordigitalmeterswillbechangedtospecifytheuseoftheFlukeModel45digitalmeter,oritsequivalent, | |||
toensureconsistent | |||
useofadigitalmeter.(3)DateWhenFullComlieneeWillBeAchievedTheprocedure | |||
changeswillbecompleted | |||
beforeApril30,1990. | |||
~~ | ~~ | ||
Attachment | |||
2toAEP:NRC:1125A | |||
Page12NRC.Violation | |||
4"10CFR50,AppendixB,Criterion | |||
XVI,asimplemented | |||
inSection1.7.16oftheDonaldC.CookOperational | |||
QualityAssurance | |||
Programrequiredthatmeasuresbeestablished | |||
toassurethatconditions | |||
adversetoqualitywerepromptlyidentified | |||
andcorrected. | |||
Inthecaseofsignificant | |||
conditions | |||
adversetoquality,themeasuresshallassurethatthecauseofthecondition | |||
wasdetermined | |||
andcorrective | |||
actiontakentoprecluderepetition. | |||
"Contrary | |||
totheabove:ThePlantAssessment | |||
GroupCommittee's | |||
reviewinMarch1989forProblemReport89-245,concerned | |||
withtheFebruary1989failureoftwosafety-related | |||
4kVbreakersT-11D6andT-1104tocloseondemandduringtestsduetolubrication | |||
hardening, | |||
failedtospecifycorrective | |||
actiontopreventrecurrence. | |||
Furthermore, | |||
noactionwastakentoinspectother4kVbreakersforcommonmodefailure.Consequently, | |||
inMarchandAprilof1989sevenadditional | |||
safetyrelatedandbalanceofplantbreakersfailedtocloseduringtesting,whichwasalsocausedbyhardening | |||
ofthelubricant | |||
onthebreakerlinkage(315/89031-04A; | |||
316/89031-04A). | |||
b.Corrective | |||
actionwasneitherpromptnoradequatetocorrectmaintenance | |||
related'roblems | |||
identified | |||
bythelicenseeinFebruary1988.InDecember1989,36ofthese71selfidentified | |||
findingsandrecommendations | |||
werereopened. | |||
Duringthisinspection | |||
manyofthesameproblemswereidentified | |||
thatreflectasignificant | |||
weaknessinthecorrective | |||
actionsystem(315/89031-04B; | |||
316/89031-04B)." | |||
ResponsetoViolation | |||
4aBasedonreviewofProblemReport89-245,whichwasaddressed | |||
intheNoticeofViolation | |||
itisourpositionthatnoactualviolation | |||
occurred. | |||
TheFebruary27,1989,condition | |||
wasidentified | |||
duringscheduled | |||
'preventive | |||
maintenance | |||
workandresultedintheproblemreport.Thatdiscovery, | |||
coupledwithasimilarcondition | |||
alsofoundduringpreventive | |||
maintenance, | |||
resultedinaPart21report.ThePart21investigation | |||
revealedthatvendor-specified | |||
information | |||
contained | |||
noinstruction | |||
forperiodiclubrication | |||
ofthebreakers. | |||
Similarbreakersusedintheplanthad,untilthattime,passedtestrequirements'he | |||
plant'sactionswhichweretakenpromptly, | |||
includedrevisionoftheprocedure | |||
basedonnewinputfromthemanufacturer, | |||
initiation | |||
ofJobOrderstoinspectallothersimilarbreakersinstalled | |||
inbothunits,andestablishment | |||
ofscheduled | |||
inspections | |||
toidentifypossiblerepetition | |||
ofthe | |||
C.I1 | C.I1 | ||
Attachment | |||
2toAEP:NRC:1125A | |||
Page13condition | |||
inthefuture.TheNoticeofViolation | |||
incorrectly | |||
concluded | |||
thatnoactionwastakentoinspectadditional | |||
breakersordevelopcorrective | |||
action.Twosubsequent | |||
problemreportswereinitiated | |||
asaresultofdeficiencies | |||
foundintheinspections | |||
andtestscoveredbyourexpandedactionforProblemReport89-245andtheassociated | |||
Part21review.Thosereportswereinitiated | |||
todocumentthesimilarconditions | |||
onthenotedbreakers. | |||
WithintwomonthsoftheMarch1,1989,Part21reporttotheNRC,theplanthadcompleted | |||
theinspections, | |||
cleanedandrelubricated | |||
thebreakersinbothunitsasrecommended | |||
bytherevisedvendorinformation, | |||
anddocumented | |||
eachcasewhenasimilarcondition | |||
wasfound.(1)Corrective | |||
ActionTakenandResultsAchievedTheresultofProblemReport89-245,whichwasreviewedbythePlantAssessment | |||
GrouponMarch17,1989,wastoinspect,cleanandlubricate | |||
similarbreakersinbothunitsanddocumenttheresults.(2)Corrective | |||
ActionTakentoAvoidFurtherViolation | |||
Procedure | |||
changesandinspections | |||
werescheduled | |||
asaresultofaddressing | |||
theproblemreportedinProblemReport89-245onsimilarbreakers. | |||
Theseactionsgenerated | |||
additional | |||
JobOrdersandcondition | |||
reportswhichwerereferenced | |||
intheinspection | |||
report.(3)DateWhenFullComlianceWillBeAchievedNoviolation | |||
occurred. | |||
ResponsetoViolation | |||
4bAsdiscussed | |||
inourresponsetoWeakness(1),AEPhastakennumerouscorrective | |||
actionstoaddresstheproblemsidentified | |||
bytheMaintenance | |||
Self-Assessment. | |||
Theseactionsinclude:othedevelopment | |||
ofaRCMProgramotheacquisition | |||
oftheNuclearPlantMaintenance | |||
(NPM)Moduleothedevelopment | |||
ofaSystemEngineerProgramotheacquisition | |||
ofNUS'sPRONETandtheservt.ces | |||
ofNUS'sprocedure | |||
writers. | |||
Attachment | |||
2toAEP:NRC:1125A | |||
Page14Inordertoeffectively | |||
implement | |||
programsasencompassing | |||
andcomprehensive | |||
asthese,significant | |||
analysis, | |||
planningandcoordination | |||
areneeded.Assuch,itwilltakeseveralyearstocompletely | |||
implement | |||
someofthecorrective | |||
actionswehaveinitiated. | |||
(1)Corrective | |||
ActionsandResultsAchievedMaintenance-related | |||
problemsidentified | |||
intheMaintenance | |||
Self-Assessment | |||
willbereviewedandresolvedasappropriate, | |||
withimplementation | |||
oftheMaintenance | |||
Improvement | |||
Plan.(2)Corrective | |||
ActionsTakentoAvoidFurtherViolation | |||
TheImprovement | |||
Planincludesmilestones | |||
andabuilt-inmechanism | |||
thatrequiresregularre-evaluation | |||
oftheplanandmonitoring | |||
ofitseffectiveness | |||
toensurethatitisproviding | |||
thedesiredresultsandthatthereiscontinuing | |||
improvement | |||
inallmaintenance-related | |||
areas'3)DateWhenFullComlianceWillBeAchievedResolution | |||
anddocumentation | |||
oftheidentified | |||
itemswillbecompleted | |||
byJune1,1991. | |||
}} | }} |
Revision as of 07:24, 29 June 2018
ML17334B364 | |
Person / Time | |
---|---|
Site: | Cook |
Issue date: | 04/11/1990 |
From: | ALEXICH M P INDIANA MICHIGAN POWER CO. (FORMERLY INDIANA & MICHIG |
To: | DAVIS A B NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM) |
References | |
AEP:NRC:1125A, NUDOCS 9004200632 | |
Download: ML17334B364 (38) | |
See also: IR 05000315/1989031
Text
\rIndiana'Achrga~PowerCompany~~080c'.663'Nl7lAMA
NTCHIGANPOWERAEP:NRC:1125A
DonaldC.CookNuclearPlantUnits1and2DocketNos.50-315and50-316LicenseNos.DPR-58andDPR-74NRCINSPECTION
NOS.50-315/89031
AND50-316/89031:
RESPONSETOVIOLATION
U.S.NuclearRegulatory
Commission
Attn:DocumentControlDeskWashington,
D.C.20555Attn:A.B.Davi.sAprilll,1990DearMr.Davis:ThisletterisinresponsetoMr.H.J.Miller'sletterdatedMarch1,1990,whichforwarded
thereportonthespecialmaintenance
teaminspection
conducted
byMr.Z.Falevitsandothersofyourstaff.Thisinspection
wasconducted
fromDecember4through8,andDecember18through22,1989,onactivities
attheCookNuclearPlantassociated
withthesupportandimplementation
ofmaintenance
toensurethatplantstructures,
systemsandcomponents
reliablyperformondemand.TheNoticeofViolation
attachedtoMr.Miller'sletteridentified
sixweaknesses
andfourSeverityLevelIVviolations
relatingtoourmaintenance
program.Theweaknesses
areaddressed
inAttachment
1tothisletter.Theviolations
areaddressed
inAttachment
2tothisletter.A14-dayextension
forourresponsewasgrantedonMarch15,1990'hisdocumenthasbeenpreparedfollowing
Corporate
procedures
thatincorporate
areasonable
setofcontrolstoensureitsaccuracyandcompleteness
priortosignature
bytheundersigned.
Sincerely,
M.P.AlichVicePresident
ldpAttachments
~)g4QOCk&2
900411pggADQcKo>oog+~~~Ipp1/00
Mr.A.B.DavisAEP:NRC:1125A
cc:D.H.Williams,
Jr.A.A.Blind-BridgmanR.C.CallenG.CharnoffNRCResidentInspector
-BridgmanNFEMSectionChief
ATTACHMENT
1TOAEP:NRC:1125A
RESPONSETONRC-IDENTIFIED
WEAKNESSES
Attachment
1toAEP:NRC:1125A
Page1NRC-Identified
Weakness(1)"Lackoforineffective
actiontocorrectnumerousselfidentified
maintenance
problemsidentified
inFebruary1988,manyofwhichwereidentified
bytheteamduringthisinspection."
ResponsetoWeakness(1)Corrective
ActionsTakenAsaresultofthe1988Maintenance
Self-Assessment
Report,AEPSCcontracted
IMPELLtoassistinidentifying
andformulating
appropriate
corrective
actionstoaddresstheself-identified
deficiencies.
Theresultsofthi,seffortareinadocumententitled,
D.C.CookPlantPMProramUradeStrateDocument,
datedNovember1988.Thisstudycontained
astrategyforAEPtoaccomplish
aplannedupgradeofthePreventive
Maintenance
(PM)ProgramattheCookNuclearPlant.Itidentified
reasonable
goalsandachievable
objectives
forthePMUpgradeProgrambasedonAEPSC/Cook
NuclearPlantphilosophy,
resources
andcapabilities.
Thespecificimplementation
tasksandstrategic
considerations
werepresented
forobtaining
thedesiredupgraderesults.Thiseffort'ot
onlyaddressed
improvements
inthePMProgramitself,butalsoexaminedrelatedorganization
andautomation
requirements
tosupporttheimprovedPMProgram.Basedontheresultsofthisstudy,numerouscorrective
actionswereinitiated
inJanuary1989.Thefirstwastheinitiation
ofareliability-centered
maintenance
(RCM)program.Thismajortaskhastwophases:analysisandimplementation.
AEPSChasbeenworkingcloselywithGeneralPhysicsontheanalysisportionthatwillformthefoundation
oftheRCMprogram.Thisworkincludes:
definingsystemboundaries
andfunctions
identifying
dominantfailuremodesdetermining
criti.cal
failuremodesandcriti.cal
components
identifying
applicable
andeffective
preventive
maintenance
taskstopreventfailurescompleting
analysisofselectedplantsystems
Attachment
1toAEP:NRC:1125A
Page2Implementation
oftheRCMProgrambeganinAugust1989withthedevelopment
ofplantprocedures,
identification
ofsystemboundaries,
andestablishment
ofanRCMdatabase.
Thefirstsyst:emanalysiswascompleted
inFebruary1990onthefeedwater
system.Analysisof22additional
plantsystems/functional
areaswilltakeplaceoverthenextthreeyears.Anotheroutgrowth
oftheMaintenance
Self-Assessment
ReportandtheAEPSC/IMPELL
studywasthedevelopment
oftheSystemEngineerProgram.ThegoaloftheSystemEngineerProgramistoprovidetrainingtoenableindividuals
toprovidetheengineering
expertise
requiredforsafe,efficient
andreliableoperation
ofsystemsforwhichtheyareresponsible.
TheSystemEngineerdischarges
thisresponsibility
byperforming
assignedtasks,andmaintaining
cognizance
ofallworkassociated
withtheassignedsystem(s).
Inaddition,
AEPSCcontracted
TENERASystemsandSoftwaretoprovideacomputerized
maintenance
management
information
system.Thissystem,referredtoastheNuclearPlantMaintenance
Module(NPM)System,discussed
inmoredetailinourresponsetoweakness(3),willallowplantstafftoinitiate,
issue,prioritize
andtrackallmaintenance
workattheplant.Thissamesoftwareiscurrently
beingusedatPacificGasandElectric's
DiabloCanyon,andPublicServiceElectricandGas'sSalemandHopeCreekGenerating
Stations.
Inaddition,
itwasrecentlychosenbyElectricite
deFranceforuseinallfiftyofitsnuclearplants.Thesethreeprograms,
RCM,SystemEngineerandNPM,arejustpartoftheactionsthatarebeingtakentorespondtotheSelf-Assessment.
TheNovember1989reorganization
ofCookNuclearPlant'smanagement
isanotherimportant
elementintheupgradeofourmaintenance
program.Theintentoftheneworganization
istoplaceemphasisonmaintenance,
outages,andhuman'resources,
Otheractions,whichhaveorarebeingtakenareasfollows:oAnAEPandCookNuclearPlantpolicyonmaintenance
wasdeveloped
andapprovedinDecember1989byAEPseniormanagement.
Anadditional
plant-specific
maintenance
policyestablished
inaccordance
withINPOguidelines
isbeingdeveloped
toclarifymaintenance
philosophies
andresponsibilities
forallmaintenance
groups
Attachment
1toAEP:NRC:1125A
Page3oCorporate
reviewshavebeenconducted,
whichhaveresultedinimprovements
beingmadetoshopareasusedbythemaintenance
groupsoStaffingstudiesarebeingperformed,
whichhavealreadyresultedinanincreaseinthenumberofengineers
andradiation
protection
technicians
onsite.oOtherprogramsofnotethataddressmaintenance
self-assessment
findingsincludethemaintenance
procedure
rewrite(SeeWeakness(6)),thelong-range
planandtheoutageguideline
development
plan.(2)BenefitsToBeDerivedFromCorrective
ActionsRCM,theSystemEngineerProgramandNPMwereinitiated
toaddressmanyoftheMaintenance
Self-Assessment's
identified
deficiencies.
Whenallofoureffortshavebeencompletely
implemented,
eachofthemajorfindingsoftheselfassessment
willhavebeenaddressed.
,Asaresultofthesecorrective
actions.weanticipate
havingastateoftheartmaintenance
programwhichwillresultinimprovedplantsafety,reliability
andaccountability.
(3)DateWhenBenefitsVillBeRealizedAspreviously
stated,westartedtheRCMPrograminAugust1989.However,weanticipate
thattheprogramwillnotbecompletely
implemented
forallthecriticalplantsystemsuntiltheendof1992.Aseachsystemisanalyzed,
benefitswillberealizedsothatwhenthisprogramiscompleted
wewillhaveafullyintegrated
preventive
maintenance
program.TheSystemEngineerProgram,likeRCM,isstillintheearlystagesofimplementation.
Adocumentwhichclearlydelineates
theresponsibilities
oftheengineers
iscurrently
inthefinalstagesofreviewandapproval.
AEPSC'sacquisition
ofTENERA'sNPMsystemwasapprovedinDecember1989.However,itwillnotbeinplaceandoperational
untilAugust1990,whendatawillbeentered.Vewillbeconducting
QAauditsorsurveillances
toaccessthestatusandeffectiveness
ofsomeofourcorrective
actionsastheydevelop.Inaddition,
theMaintenance
Improvement
Planwillreviewandresolve,asappropriate,
theMaintenance
Self-Assessment
items'heImprovement
Planincludesmilestones
andabuilt-inmechanism
thatrequiresregularre-evaluation.
Attachment
1toAEP:NRC:1125A
Page4Whilewearealreadyrealizing
benefitsfromourefforts,wedonotanticipate
thefullbenefitforseveralyears.Inordertoeffectively
implement
programsasencompassing
andcomprehensive
asthese,significant
analysis,
planningandcoordination
areneeded.Asaresult,theirbenefitswillnotbefullyrealizeduntilmid1993.
Attachment
1toAEP:NRC:1125A
Page5NRC-Identified
Weakness(2)"Anineffective
preventive
maintenance
programthatresulted,
forexample,infailuresof4KVcircuitbreakers"
ResponsetoWeaknessWeconcurthatthePreventive
Maintenance
Programcanbeimprovedand,aspreviously
discussed,
wearetakingstepstodoso.However,CookNuclearPlant'savailability
in1989isevidencethatthepresentpreventive
maintenance
programiseffective.
During1989,CookNuclearPlantgenerated
12millionnetMWHRS,themostsince1984.The69.3%availability
forUnit1in1989contributed
toanaverageavailability
of79.4%since1985'lthoughUnit2overallavailability
hasnotbeenashighduetosteamgenerator
tubedegradatidn,
its74.4%availability
in1989wasthehighestsince1983.OnDecember8,the111-dayrecordforthelongestrunwithbothunitsoperating
wasbroken.Thisrecordwasextendedto140dayswhenUnit2wasbroughtoff-lineforasurveillance
outageonJanuary6,1990.Unit1ended1989withitslongestrunof175daysandcontinued
operating
untilMarch17,1990(aCookNuclearPlantrecordrunof251days)whentheunitwasbroughtofflineforaplannedsurveillance
outage.Asdiscussed
inourresponsetoNRCviolation
(2)oftheinspection
report,the4KVcircuitbreakersfailurewasdetectedduringpreventive
maintenance
testing.Asaresult,appropriate
corrective
actionwas.subsequently
takenwhichresultedinimprovements
toour4KVbreakers.
Also,wenotifiedtheindustryoftheproblemviaaPart21report.
Attachment
1toAEP:NRC:1125A
Page6NRC-Identified
Veakness(3)"Anextensive
backlogofnon-outage
corrective
maintenance
joborderspartlycausedbylackofintegrated
planningandscheduling
methodology."
ResponsetoWeakness"Maintaining
theCookNuclearPlantinvolvesthecompletion
ofapproximately
20,000JobOrdersannually.
Therelativepriorities
ofjobschangefrequently
duetoanumberoffactors,theprimaryreasonbeingplantconditions.
Managingtheinformation
contained
withinthebacklogofyet-to-be
completed
JobOrderscanbecriticaltoplantavailability
andreliability.
Theseeffortsarepresently
hamperedbythelogistics
ofpaperfilingsystemsandcomputertrackingsystemsthatlackneededflexibility
inhardwareandsoftware.
(1)Corrective
ActionsTakenTheCookNuclearPlantInformation
Management
System(IMS)plan,approvedfordevelopment
inFebruaryof1989identified
ninecomputersystemmodulesthat,whencompleted,
willformasingle,integrated
information
management
system.Thisautomated
information
systemwillbeusedbybothplantsiteandcorporate
personnel
tosupportplantoperation
andmaintenance.
Itwillprovideforthescheduling
andinitiation
ofmaintenance
tasksandsupporttheassignment
ofresponsibilities
andaccountabilities
forthesetasks.Specifically,
formaintenance,
theNuclearPlantMaintenance
Module(NPM)oftheCookNuclearPlant'sIMSplanwillallowplantstafftoinitiate,
issue,prioritize,
andtrackallmaintenance
workattheplant.TheNPMmoduleoftheIMSplanwillalsomaintainahistoryofmaintenance
work.Theprimaryobjectives
oftheNPMmodulearetoimproveplantavailability
andtooptimizetheuseofplantresources
withtheoverallgoalofreducingplantmaintenance.
TheNPMsystemisdesignedtoallowanyNPMusertoinitiateastructured
requestthattheuserbelievesshouldbereviewedand,ifwarranted,
actedupon.Thisactionrequestfeatureprovidesaprocessforscreening
thoseactionsrequiring
work,andwillserveasafocalpointforinitiating
andtrackingJobOrders.Plantpersonnel
willenterdataintotheNPMsystemdefiningthecomponent
thatneedsworkandbrieflydescribing
thatwork.Thesystemisdesignedtoeliminate
allpaperinthisprocessexcepttheactualJobOrderitself.
Attachment
1toAEP:NRC:1125A
Page7ThereviewsthattakeplaceintheJobOrdersystemareperformed
on-line.Thison-linecapability
allowsforpendingJobOrderstobesortedinvariouswaysandthereviewing
individuals
have'mmediate
accesstothisinformation.
Oncereviewsareperformed
theactualJobOrderscanbeprintedfortheworktobeperformed.
OnceaJobOrderhasbeeninitiated,
startingfromtheveryfirstentryintothesystemandnotjustfromthetimeitgetsprinted,theJobOrderprocessing
systemcantrackthestatusoftheJobOrder.Thisisaccomplished
throughtheuseofstatuscodefields.Someofthecodesrepresent
situations
suchaswaitingformaterials,
orwaitingforapprovalofthereviews,orothertypesofconditions.
Thisfeatureisveryhelpfulforplanningandscheduling
themanyJobOrdersinthesystem.TheNPMsystemwillpermittheplantstafftoassignspecificJobOrders,attheactivitylevel,toascheduled
date,crewandsupervisor.
Uponcompletion'f
thecrewassignments
andconfirmation
ofpermitrequirements,
thesystemproducesasupervisory
assignment
reportandprintstheJobOrder.Thecompleted
workpackageincludestheJobOrder,equipment
descriptions,
partslist,andtestingformsalongwithotherneededdocuments.
OncetheworkrelatedtoaJobOrderhasbeencompleted
andtested,theJobOrderisreviewedandclosedout,on-line.TheNPMsystemmaintains
acompletehistoryofallcompleted
andclosed-out
JobOrders.ThisfeatureallowsforrapidaccesstoallhistoryonJobOrders.TheNPMsystempreventsaJobOrderfrombeingclosed-out
untilallreviewsandtestshavebeencompleted.
Znaddition,
theNPMsystemwillbearepository
forpreviousrepetitive
tasks.Thisfunctioneliminates
theneedforindividuals
torecreateJobOrdersthatarerepetitive
innature,TheNPMsystemwillautomatically
generatetheJobOrders,,according
totheappropriate
duedates,orasdirectedbyaplanner.TheNPMsystemwillalsoprovideforcontinuous
monitoring
ofsurveillance
testsandpreventive
maintenance
worktomeetregulatory
orplantrequirements.
Oncetherepetitive
orpreventive
maintenance
JobOrdersarecreated,theyareavailable
forreviewsandexecutions
inthesamemannerasanyoftheotherJobOrders.ThissystemwillalsobeusedtodevelopJobOrdersforplannedoutagessuchasrefueling
outages.
Attachment
1toAEP:NRC:1125A
Page8(2)BenefitsToBeDerivedFromCorrective
ActionsThedataenteredintotheNPMsystem,andtheprocessing
thatthesystemdoeswiththisdata,willeliminate
themultiplemanualdataentrystepsofourpresentprocess.Eliminating
redundant
manualsystemsisofsignificance
itself.However,moreimportantly
aretheanticipated
improvements
inplantavailability
andlaborproductivity.
Alongwithimprovedabilitytoplanandscheduleworkcomesanincreased
amountoftimeavailable
formorecarefulconsideration
ofotheraspectsoftheworktobeperformed,
forexample,personnel
safety.Improvements
canbeexpectedandwillcertainly
bestrivedfor.TheNPMsystemwillalsoidentifyandcoordinate
maintenance
onrelatedequipment
andsystems,thusdecreasing
downtimeoncomponents
removedfromservice.Quickaccesstotheinformation
intheNPMdatabasesmakesthesupervisors
inboththeoperations
andmaintenance
areasmoreawareofJobOrderprogress.
Itisanticipated
thattheNPMsystemw'illhelpusrealizeourgoalofanon-outage
corrective
maintenance
joborderbacklognotinexcessof90days.(3)DateWhenBenefitsWillBeAchievedWecurrently
anticipate
havingthecomputerized
automated
maintenance
systeminplaceandoperational
byAugust1990.Atthattime,datavalidation
andloading,procedure
changesandtrainingofpersonnel
willbegin.
Attachment
1toAEP:NRC:1125A
Page9NRC-Identified
Weakness(4)"Poormaterialcondition
especially
asevidenced
bythehighnumberofoil,steamandwaterleaks."ResponsetoWeakness(1)Corrective
ActionsTakenWhileitisAEPSC'spolicytokeepallofitsfacilities,
ingoodmaterialcondition,
werecognize
theneedforimprovement
inthisarea.Asaresult,themanagement
oftheCookNuclearPlanthaslaunchedaconcerted
efforttoimproveplantmaterialcondition.
Thisisevidenced
bytheallocation
offundstosupportthefollowing
physicalimprovements
thatarecurrently
takingplace:oAuxiliary
buildingpaintingoContaminated
equipment
storageareaexpansion
IoDecontamination
arearedesignoImprovedlightingoInstallation
of18personnel
wholebodycontamination
monitorsItisCookNuclearPlantpolicythatnoleakisconsidered
acceptable.
Consequently,
duringthe1988/1989
refueling
outageswerefurbished
about1,780valvesandpackedthemwithChesterton
packing.Abreakdown
ofthiseffortisasfollows:Unit1Unit2TotalAuxiliary
BuildingContainment
TurbineHallMiscellaneous
254130225211502807009255071250504Nevertheless,
asubstantial
numberofleaksstillexistintheauxiliary
building,
rangingfromsmalltracesofdriedboricacidtodripping.
Theseleakshavebeenenteredintoacomputerdatabase,havebeenchalkeddown,andjobordershavebeenwritten.Theleaksarecurrently
beingprioritized
andeffortswillbemadetorepairthemduringthenextrefueling
outage,ifnotbefore.
Attachment
1toAEP:NRC:1125A
Page10Theplantmanagerhasreaffirmed
hiscommitment
togoodplantmaterialcondition
andpersonalaccountability
bysendingamemorandum
toeachemployee.
Thiscommitment
hasbeensupported
bycontinued
radiation
workerawareness
training,
andoperatortrainingonventinganddraining.
Inaddition,
decontamination
effortscontinue,
whichhavealreadyreducedthecontaminated
areafromapproximately
45,000feetin1986tothecurrent25,000feet(excluding
laydownareas).Ourgoalistoreducethesecontaminated
areasto20,000squarefeetin1990and10,000squarefeetpriortotheoutagein1991.(2)BenefitsToBeDerivedfromCorrective
ActionsTherearenumerousbenefitsgainedfromhavingtheplantingoodphysicalcondition,
themostimportant
ofthesebeingincreased
plantsafetyandreliability.
Arelatedbenefitisimprovedradiation
protection
andworkersafety.However,anotherimportant,
butlessquantifiable
benefitistheimprovement
toworkermorale.(3)DateWhenBenefitsWillBeRealizedWhilemaintaining
theplantingoodphysicalcondition
isanongoingprocess,weanticipate
majorimprovements
withinthenextyear.Therefueling
outagewillfacilitate
therefurbishment
ofvalises,aswellasotherrepairsandmodifications.
Attachment
1toAEP:NRC:1125A
Page11NRC-Identified
Weakness(5)"Inadequate
trending,
rootcauseanalysisandactiontocorrect,forexample,numerousleakingsafetyreliefvalves."ResponsetoWeakness(1)Corrective
ActionsTakenThisweaknessisbeingaddressed
bythreeprograms:
theNPMsystemwhichisdiscussed
indetailinourresponsetoweaknesses
(1)and(3),theSystemEngineerProgram,discussed
inourresponsetoweakness(1),andtheRCMProgramdiscussed
inourresponsetoweakness(1).(2)BenefitsToBeDerivedfromCorrective
ActionsTheNPMsystemwillprovideforacompletecomponent
history.Thecomponent
historywillprovideachronological
listingofwork,modifications
orinspections
thathavebeenperformed
onaparticular
component.
Thisprocesscreatesanindexedhistorical
recordforcomponents
orfunctional
equipment
groupsandcatalogscompletion
dates,failurecodes,as-foundandas-leftconditions,
partsreplaced,
testresults,etc.TheSystemEngineers
areexpectedtoidentifyandtrendappropriate
systemparameters,
withthegoalofobtaining
pertinent
dataforsystemperformance
andreliability
monitoring.
Theparameters
trendedshallbeperiodically
reviewedandapprovedtoallowtimelypreventive
orcorrective
actionstobeimplemented.
Basedonthetrendeddata,theSystemEngineerisexpectedtorecognize
significant
system/component
degradation
orabnormaloperating
conditions
frombothahistorical
basis,aswellascurrentstatus.TheSystemEngineermayrequirethesupportoftechnical
expertstoanalyzespecificareasofconcernandwillworkcloselywithourCorporate
NuclearEngineering
Divisionengineers
inthisregard.TheSystemEngineers
areexpectedtoperformrootcauseanalysesonthesystemsassigned.
Consequently,
theSystemEngineers
willbetrainedinrootcauseanalysis.
Inaddition,
theSystemEngineerisexpectedto:Evaluatesystem/component
failureimpactonplantsafetyandunitpoweroperations
Prepareandperformspecialsystem/component
performance
tests.
Attachment
1toAEP:NRC:1125A
Page12TheRCMProgramwt.llcontribute
toresolving
thisissuebyidentifying
dominantfailuremodesandcriticalcomponents.
(3)DateWhenBenefitsWillBeRealizedAspreviously
stated,weexpecttheNPMsystemtobeinplaceandoperational
inAugust1990.Atthattime,personnel
traininganddataloadingwillbegin.Severalsystemengineers
havebeenassignedatCookNuclearPlantandbenefitshavealreadybeenrealizedfromthisprogram.Aneffortiscurrently
beingmadetorecruitSystemEngineers.
However,weanticipate
itwilltakeatleastayearbeforetheprogramisfullystaffed.
Attachment
1toAEP:NRC:1125A
Page13NRC-Identified
Weakness(6)"Inseveralinstances
procedures
werenotfollowed,
werepoorordidnotexistespecially
inthebalanceofplantarea."ResponsetoWeakness(1)Corrective
ActionsTakenKeytothesafeandefficient
operation
ofanynuclearpowerplantisstrictadherence
toprocedures.
Assuch,employees
areshownduringtheNuclearGeneralEmployeeTraining(NGET)classes,avideotape
ofDavidWilliams,
Jr.,SeniorExecutive
V.P.,Engineering
andConstruction,
mandating
theadherence
toprocedures.
ItisAEPSC'slong-standing
policythatfailuretofollowprocedures
willresultindisciplinary
action.Inorderforthispolicytohaveanybenefit,well-written
andaccurateprocedures
mustbeinplace.Consequently,
AEPSCispurchasing
PRONETandtheservicesofconsultant
procedure
writerstoupgradeorwrite690maintenance
procedures
(268maintenance,
422I&C).Criticalbalanceofplantcomponents
willbeaddressed
astheyariseintheRCMprogram.TheMaintenance
Improvement
Planprovidesguidancethatclearlydefineswhatprocedure
compliance
is.Inaddition,
aprocedure
writer'/user's
guidewilladdressthecircumstances
forchangingaprocedure
toensureprocedural
compliance.
(2)BenefitsToBeDerivedfromCorrective
ActionsPRONETisastateoftheartcomputersystemthatintegrates
writer'sguidelines,
wordprocessing,
graphicsanddatabasefunctions
intoacentralized
procedure
management
system.Development,
commitment,
scheduling
andreporting
functions
willbecontrolled
bythismenu-driven
network.Thisintegrated
approachwillresultinaprogramthatreducesdevelopment
timeandprovidesefficient
long-term
procedure
maintenance
andcommitment/reference
tracking.
(3)DateWhenBenefitsWillBeRealizedAlthoughaconsultant
willtrainplantstaffontheuseofPRONET,thebulkoftheprocedure
upgradeworkwillbeperformed
byconsultant
personnel.
Byusingcontractworkerswewillnotimpacttheplantstaff.Iftheexistingstaffwereused,itisanticipated
thattheeffortwouldtakefourtofiveyears.Thisisconsidered
tobeanunacceptable
timeframeforthiswork.Byusingcontractworkers,wewillobtainprofessionally
preparedprocedures
inareasonable
timeframe.Theeffortisscheduled
tobecompleted
byDecember1991.
ATTACHMENT
2TOAEP:NRC:1125A
RESPONSETONRC-IDENTIFIED
VIOLATIONS
Attachment
2toAEP:NRC:1125A
Page1NRCViolation
1"10CFR50,AppendixB,Criterion
V,asimplemented
bySection1.7.5oftheDonaldC.CookNuclearPlantOperational
QualityAssurance
Programrequiresthatactivities
relatedtoqualitybeprescribed
bydocumented
instructions,
procedures,
anddrawings,
thatthoseactivities
beaccomplished
inaccordance
withthoseinstructions,
procedures
anddrawings,
andthatinstructions,
procedures
ordrawingsincludeappropriate
quantitative
orqualitative
acceptance
criteriafordetermining
thatimportant
activt,ties
havebeensatisfactorily
accomplished.
a~Procedure
PMI-2290,
"JobOrders,"Revision8,requiredinSections4.4.8and4.4.8.3thatuponcompletion
ofthephysicalwork,thejobordertagsberemovedanddiscarded.
Contrarytotheabo~e,tags15119,029643,B012209,B016950,B016832,andB017240werenotremovedalthoughthejoborderswerecancelled
orcompleted.
Asaresult,statusofequipment
condi.tion
remainedindeterminate
(315/89031-01A;
316/89031-01A)
~b.RequestForChange12-2180requiredinstallation
of200%overloadmotorprotection
andthatthethermaloverloadbesetatthelowtripcurrentrating.Contrarytotheabove,onDecember19,1989,theinspectors
observedthatthethermaloverloadheaterassociated
withresidualheatremovalloopisolation
motor-operated
valveICM-111wassetatthehightripcurrentrating.Numerousadditional
thermaloverloads
inthedieselgenerator
motorcontrolcenterwerealsoobservedtobethewrongsizeorsetatthewrongcurrentrating,whichwillresultinpremature
removalofoperating
voltagefromthemotors(315/89031-01B;
316/89031-01B)
~c~Procedure
PMI-2030,
"Document
Control,"
Revision10,failedtoincluderequirements
fortheMasterDrawingIndexestobereviewedbyintendedusersforthelatestasbuiltdrawingslocatedintheplantmasterfile.Consequently,
drawingsissuedbythedocumentcontrolcenterforfieldverifications
werenotthelatestasbuiltdrawingsorrevisions
(315/89031-01C;
316/89031/01C).
The"PumpOperator's
Data"manualandthevendormanualfor'heAuxiliary
(AFV)pumprequiredthatthepumppackingbeadjustedwhilethepumpisoperating.
Contrarytotheabove,thisrequirement
wasnotincorporated
intotheAFVmaintenance
procdures
[sic).Althoughnoproblemswerenoted,inadequate
attention
tothisrequirement
couldresultinrotorseizure,scoredshaftsleeves,orburnedpacking(315/89031-01D;
316/89031-01D).
Attachment
2toAEP:NRC:1125A
Page2Procedure
12THP6030IMP.014"Protective
RelayCalibration",
Revision8,Step8.1.2-2specified
thatblackelectrical
tapebeusedwhencleaningthediskanddragmagnetmechanism
onTimeOvercurrent
(IAC)relays.Contrarytotheabove,onDecember5,1989,atechnician
wasobservedusinganunusedcalibration
stickertocleanthe2ABEDGTimeOvercurrent
testrelay.Asaresult,cleanliness
ofthecontactswasquestionable
(315/89031-01E;
316/89031-01E).
f.Procedure
PMI-2010"PlantManagerandDepartment
HeadInstructions,
Procedures
andIndex,"Revision17,PolicyStatement
3.1,Section3requiredthat"doubleasterisked"
procedures
forplantactivities
be"in-hand"
whenimplementing
theprocedure.
Contrarytotheabove,onDecember6,1989,theinspector
observedanoperatorrackin"2A"TrainReactorTripBypassBreakerwithouthaving"inhand"doubleasterisked
procedure
~12-OHP4021.082.018
"RackingInandOutReactorTrip,ReactorTripBypassandMGSetOutputBreakers,"
Revision2.Eventhoughnoadverseaffectswerenoted,inthepastundersimilarcircumstances,
areactortripoccurred(315/89031-01F;
316/89031-01F).
Procedure
PMI-2010,
"PlantManagerandDepartment
HeadInstructions,
Procedures
andIndex,"Revision17,requiresinSection3.14.1thatalleffective
instructions
andprocedures
bereviewednolessfrequentthanonceeverytwoyears.Contrarytotheabove,maintenance
procedure
MHI2070,MHI7090,PMI4050,12THP6030IMP~071,and12THPIMP.062werenotreviewedinthelasttwoyears.Asaresult,theprocedures
werenotupdatedtoreflectfeedbackandchangestopreventive
maintenance
activities
(315/89031-01G;
316/89031-1G)."
ResponsetoViolation
laPlantprocedure
PMI-2290requiresthattagsplacedatornearequipment
needingrepairberemovedwhentheitemisrepairedoriftheJobOrderiscancelled.
Asnotedinthetext,sixJobOrdertagswerefoundintheplantforworkthathadbeencancelled
orcompleted
whichconstitutes
failuretofollowprocedure.
Theconclusion
madeinInspection
Report89031wasthatequipment
statuswas"indeterminate."
WhilethepresenceofJobOrdertagswascontrarytotherequirements
ofPMI-2290,
thestatusofequipment/components
involvedwouldnotbeaffected.
Theinformation
placedonatagidentifies
topersonnel
1)thataJobOrderhasbeenwrittenforrepairwithnumbernoted,2)thenatureofrepairs/adjustments
requiredasdetermined
bythepersoninitiating
theJobOrderand3)helpslocatethespecificcomponent.
Byitself,aJobOrdertaghasnoimpactonsystemorequipment
operability,
does
Attachment
2toAEP:NRC.:1125A
Page3notindicatethatequipment
hasbeentaggedout,anddoesnotdirectanyotheractivityinvolving
theequipment.
Othersystemssuchastheclearance
permitsystemlogsandthedeficiency
logsindicatetheequipment
status.(1)Corrective
ActionTakenandResultsAchievedJobOrdertagsidentified
duringtheinspection
weresubsequently
removedtoachievecompliance
withapplicable
sectionsofPMI-2290.
(2)Corrective
ActionTakenToAvoidFurtherViolation
ThePlantManagerwilli.ssueamemoonprocedural
compliance
toensurethatallpersonnel
arefullyawareofthemeaningofcompliance,
consequences
offailureandwhatactionstotake~whenaprocedure
cannotbefollowedaswritten.TheMaintenance
Improvement
Planincludesissuanceofadepartment
policyonprocedure
compliance.
Includedwillbeguidanceonthemonitoring
oftheeffectiveness
ofprocedure
compliance.
Alsoaprocedure
writer'/user's
guidewilladdressthecircumstances
forchangingaprocedure
toensureprocedural
compliance.
(3)DateWhenFullComlianceWillBeAchievedThefinaldraftofthepolicywillbeissuedonJuly15,1990.Guidanceontheeffectiveness
monitoring
willbeissuedonAugust15,1990.ThePlantManager's
memowillbeissuedonMay1,1990.ResponsetoViolation
lbTheNoticeofViolation
identified
thatthermaloverloads
intheplanthadbeeninstalled
atanincorrect
tripcurrentrating.Asaresultoftheinspection,
plantpersonnel
investigated
theproblemandaddressed
itinProblemReport90-81.(1)Corrective
ActionTakenandResultsAchievedTheimproperpositioning
and/ormis-sizing
oftheoverloadheatersresultedfromerrorsmadeduringinitialinstallations.
Twentyoverloads
wereinspected
andevaluated
byplantandAEPSCengineers.
Elevenwerefoundtob'ecorrect.Onewasfoundonabreakerforaresistive
heaterwhereoverloadprotection
wasnotconsidered
criticalasmoldedcasecircuitbreakersprotection
wasprovided.
Onfourbreakers(including
ICM-111)theas-foundheatersizeagreedwiththecalculated,
butarrowpositiondidnotagree.Fullloadampswasatthedividingpointforselecting
upordownposi.tion.
Slightchangesinmotorprotection
resultedbutdidnotaffecttheoperability
ofload.FourfeedersonBOPwerefoundtobemis-sized.
Ofthosefour
Attachment
2toAEP:NRC:1125A
-Page4onewasmis-sized
toadegreethatreplacement
wasneededtoensureadequateprotection.
Ofthethreeotheroverloadheaters,thoughimproperly
set,wouldhaveprovidedthermaloverloadprotection
forequipment.
JobOrderstocorrectthesesettingsbyOctober30,1990,havebeenwritten.(2)Corrective
ActionTakenToAvoidFurtherViolation
Inthecourseoftheplant'sinvestigation
itwasdetermined
thatthemis-sizing
and/ormispositioning
ofthethermaloverloads
hadoccurredduringinitialinstallation
in1977and1978.Lackingvendorinformation,
calculations
weremostlikelydeveloped
byplantpersonnel
forpositions/sizes
whichinsomeofthecases,provedincorrect.
Thedesignchangeprocesshasevolvedsincethattimetoalevelthatreasonably
ensuresthatrepetition
ofasimilarcondition
willnotoccur.Specifically,
generalprocedures
nowrequirethatdesigncalculations
beverifiedanddocumented
byqualified
personnel.
(3)DateWhenFullComlianceWillBeAchievedBasedontheengineering
evaluation
completed
January15,'990,thedeficiencies
inthethermaloverloadheatersettingswouldnothaveaffectedtheoperability
oftheICM-111breaker.Otherdeficiencies
didnotdegradethethermaloverloadprotection
oftheequipment
breakers.
Currentprocedures/practices
shouldpreventrecurrence
ofthisproblem.ResponsetoViolation
lcInthecourseoftheinspection
itwasfoundthataplantinstruction
utilizedfordocumentcontrol(drawings)
contained
noprovision
mandating
thattheuseroftheindexverifythatitwasthemostrecentupdate.Weconcurwiththeinspector's
conclusion
thataninstruction
tousersoftheMasterDrawingIndextoensurethatitreferences
up-to-date
as-builtdrawingsshouldbeincludedinprocedures.
(1)Corrective
ActionTakenandResultsAchievedAsaresultoftheinspection,
PMI-2030,
"Document
Control,"
wasrevisedtoinstructaMasterDataIndexusertoensurethatitreflectsthelatestas-builtdrawingslocatedintheplant'smasterfile.(2)Corrective
ActionTakenToAvoidFurtherViolation
Revision11toPMI-2030isbeingroutedforapprovalfromplantmanagement.
Therevisionaddresses
theinspector's
concernnotedintheNoticeofViolation.
IAttachment
2toAEP:NRC:1125A
Page5(3)DateWhenFullComlieneeWillBeAchievedTherevisedversionofPMI-2030willbeeffective
byMay1,1990.ResponsetoViolation
ldProcedural
revisiontoincorporate
adirection
torunapumpinordertoproperlyadjustpackingisnotviewedasnecessary.
Personnel
performing
packingadjustments
meettherequirements
ofANSIStandardN18-1(4.5.3).Consistent
withthatstandard,
maintenance
personnel
receiveformaltraininginsubjectsassociated
withtheirposition.
Includedintheplant'strainingisacourseonpumpsthatdirectlyreferences
thecorrectmethodology
foradjusting
thepackingonpumps.Thisteachesmaintenance
personnel
thatadjustments
willonlybemadetopackingwhenthepumpisoperating.
AsrequiredbyANSIStandardN18-7,Section4.1(2),plantprocedures
aredeveloped
withtheobjective
ofproviding
adequateinformation
topersonnel
involvedinagiventaskconsidering
theskilltheyareprovidedthroughthetrainingprogram.(1)Corrective
ActionTakenandResultsAchievedThosepersonswhowouldbeinvolvedinpumppackingworkarehiredandtrainedconsistent
withANSIN18-1.(2)Corrective
ActionTakentoAvoidFurtherViolation
Thehiringpractices
andtrainingprogramshaveprovenadequatetopreventproblemsduetopumppacking(3)DateWhenFullComlianceWillBeAchievedNoviolation
occurredaspractices
areinaccordance
withN18-1andpersonnel
arefullyqualified.
ResponsetoViolation
leWhiletheintentofStep8.1.2-2ofmaintenance
procedure
12THP6030.IMP.014
wastoensurethattechnicians
performing
cleaningwouldutilizetapeorsimilaradhesive-backed
material.
Blackelectrical
tape,wasspecified
becauseitisacommonlyavailable
item.However,useofacalibration
stickerdid-constitute
aviolation
oftheprocedure
aswritten.(1)Corrective
ActionTakenandResultsAchievedMaintenance
supervision
reviewedtheneteffectofutilizing
thestickerinthecourseofcleaninganddetermined
thatsatisfactory
resultswereobtained.
Nore-cleaning
wasdeemed
Attachment
2toAEP:NRC:1125A
Page6necessary.
12THP6030.IMP.014
hadbeenrevisedviaachangesheetinitiated
April2,1990,toremovereference
toblackelectrical
tape.(2)Corrective
ActionTakenToAvoidFurtherViolation
ThePlantManagerwillissueamemoonprocedural
compliance
toensurethatallpersonnel
arefullyawareofthemeaningofcompliance,
consequences
offailureandwhatactionstotakewhenaprocedure
cannotbefollowedaswritten.TheMaintenance
Improvement
Planincludesissuanceofadepartment
policyonprocedure
compliance.
Includedwillbeguidanceonthemonitoring
oftheeffectiveness
ofprocedure
compliance.
Alsoaprocedure
writer'/user's
guidewilladdressthecircumstances
forchangingaprocedure
toensureprocedural
compliance.
(3)DateWhenFullComlieneeWillBeAchievedThefinaldraftofthepolicywillbeissuedonJuly15,1990.Guidanceontheeffectiveness
monitoring
willbeissuedonAugust15,1990.ThePlantManager's
memowillbeissuedonMay1,1990.ResponsetoViolation
lf(1)Corrective
ActionTakenandResultsAchievedTheAuxiliary
Equipment
Operator(AEO)involvedinthiseventhadreceivedtrainingontheoperation
ofreactortripbreakersandtheexistence
oftheprocedure
priortothisevent.TheAEO,however,overlooked
thereactortripbreakerprocedure
wasrequiredtobe"inhand"wheneverperforming
rackingoperations.
Althoughtherackingevolution
wasdoneinaccordance
withthe.procedure
requirements,
thiseventwasaviolation
becausetherequirement
tohavetheprocedure
"inhand"wasnotsatisfied.
Amemorandum
wasissuedtoOperations
personnel
onJanuary19,1990,toremindthemofthe"inhand"requirement
forthereactortripbreakerprocedure.
(2)Corrective
ActionToBeTakenToAvoidFurtherViolation
Theroutinesurveillance
procedures
forreactortripbreakertestingwererevisedonDecember13,1989,toreference
therequirement
forhavingthereactortripbreakerrackingprocedure
"inhand"fortherackingevolutions.
Thestartupsurveillance
procedures,
whichrequirerackingofthereactortripbreakers,
willberevisedbyJune4,1990,toreference
therequirement
forhavingthereactortripbreakerprocedure
"inhand."
Attachment
2toAEP:NRC:1125A
Page7Duringtheconcluded,
procedures
Therefore,
pasttwoyears,QAaudits/surveillances
haveexceptfora"fewisolatedcases,"doubleasterisked
haveinfactbeen"inhand"whenrequired.
nogenericprogrammatic
problemexists.(3)DateWhenFullComlianceWillBeAchievedFullcompliance
wasachievedonDecember6,1989,whenthe'involved
AEOwasreinstructed
ofthe"inhand"procedural
requirement.
ResponsetoViolation
lgFiveprocedures/instructions
werecitedintheNoticeofViolation
asnothavingbeenreviewedwithinthetwo-yearlimitestablished
inplantprocedure
PMI-2010.
However,ineachcasethedocuments
hadbeenreviewedanddocumentation
tothateffectwasonfile.Uponrequestoneoftheinspectors
wasprovidedwithbiannualreviewdocuments
forIMP.071andIMP.062.Theinstruction
doesnotrequireanapprovedrevisionwithintwo.years,onlyareviewpriortosuchrevision.
Thisinformation
maynothavebeenadequately
communicated.
(1)Corrective
ActionTakenandResultsAchievedFurtherreviewoftheNoticeofViolation
bytheplantidentified
thatprocedures/instructions
notedhadreceivedreviewasrequiredbyPMI-2010,
Rev.17.(2)Corrective
ActionTakentoAvoidFurtherViolation
Trackingandreviewofprocedures
ispresently
adequate.
(3)DateWhenFullComlianceWillBeAchievedNoviolation
occurred.
Attachment
2toAEP:NRC:1125A
Page8NRCViolation
2"10CFR50,AppendixB,Criterion
VIII,asimplemented
bySection1.7.8oftheDonaldCDCookOperational
QualityAssurance
Programrequiredthatmeasuresbeestablished
fortheidentification
ofmaterials,
partsandcomponents
suchasbypartnumber,serialnumber,orotherappropriate
meansontheitemorrecordstraceable
totheitemthroughout
fabrication,
installation
anduseoftheitem.""Contrary
totheabove,identification
ofmaterials
andcomponents
fortraceability
wasnotaccomplished
forcableextension
portionsandaluminumsplicingsleevesforconnections
toseveralsafety-related
motorcontrolcentersinstalled
undertheRequestForChange1482modification
(315/89031-02;
316/89031-02)."
ResponsetoViolation
transition
pieces(sleeves)
tosplicecoppertoaluminumcablesinvariousmotorcontrolcenters.PerRFCinstructions,
thetransition
piecesweretobeinstalled
inaccordance
withEngineering
DesignSpecification
(EDS)607andEDS608'heinstallation
tookplacebetweenJuneof1979andSeptember
of1981whenthefinalsummarywasissued.Asearchofthecompleted
RFCpackage(including
installation
joborders)andofthemicrofilm
ofthecompleted
joborderpackagesrevealednodocumentation
oftheparts(sleeves)
usedfortheinstallation.
Individuals
whowereinvolvedwiththeMaintenance
Department
atthattimestatedthatpersonnel
wouldhaveinstalled
thetransition
piecespertheEDSasstatedintheRFC.Inadequate
documentation
ofmaterialinstalled
byaJobOrderduringthedesignchangeprocesswastherootcauseofthisviolation.
Additionally,
therewereinadequate
reviewofthecompleted
jobordersandthedesignchangepackageuponcompletion.
(1)Corrective
ActionTakenandResultsAchievedTheinstallation
tookplaceapproximately
10yearsagoandwasperformed
inaccordance
withEDS608,whichwasreferenced
intheRFCpackage.Actualapplication
forthepasttenyearshasfunctionally
demonstrated
theadequacyofsubjectmaterials'
Attachment
2toAEP:NRC:1125A
Page9(2)Corrective
ActionTakenToAvoidFurtherViolation
Currentprocurement/dedication
practices
ensureproperdocumentation
isdeveloped
todemonstrate
controloverthesuitability
ofmaterial,
partsandcomponents.
(3)DateWhenFullComlianceWillBeAchievedCurrentprocedures/practice's
shouldpreventrecurrence
ofthisproblemandensurefuturecompliance.
Attachment
2toAEP:NRC:1125A
Page10NRCViolation
3"10CFR50,AppendixB,Criterion
XI,asimplemented
bySection1.7.11oftheDonaldC.CookOperational
QualityAssurance
Programrequiredthatatestprogrambeestablished
toassuretestingtodemonstrate
thatsystemsandcomponents
willperformsatisfactorily
inserviceinaccordance
withtestprocedures
whichincorporate
requirements
andacceptance
limitscontained
inapplicable
designdocuments,
andthatadequatetestinstrumentation
wasavailable
andused.""Contrary
totheabove,testinstruments
werenotsensitive
oraccurateenoughtoverifythecalibration
oftheundervoltage
relaysthatactuatetheEmergency
DieselGenerators.
Procedure
2THP6030IMP.250,"4kVDieselStart,4kVESSBusUndervoltage
RelayCalibration,"
Revision7,Section3.0,requiredtheuseofaWestinghouse
typePA-161ACanolog[sic]voltmeter
oritsequivalent
withequalorbetteraccuracyandadequaterangetomeasurethedesiredparameters.
However,thevoltmeter
hadatolerance
of+1.5voltsthatwasnotsufficiently
accuratetomeasurethedesiredparameter
of90.3to91.8voltsspecified
inTechnical
Specification
3.3.2.Inaddition,
thevoltmeter
indicated
tothenearestwholevoltanddidnothavedivisionmarkingsbetweenthenumbers.Technicians
hadtointerpolate
resultsandrecordvaluestothenearesttenthofavoltwhilethevoltmeter's
dialindicator
wasmovingintheincreasing
ordecreasing
direction.
Furthermore,
thetechnicians
usedhandsignalstocommunicate
themomenttheundervoltagerelayoperated.
Basedontheinaccuracy
andinsensitivity
ofthevoltmeter,
andpoortestingtechnique,
resultsoftheundervoltage
testwerenotconclusive
(315/89031-03;
316/89031-03)."
ResponsetoViolation
3Themeterusedwasfirstspecified
intheoriginalprocedure
developed
beforeinitialplantstart-up.
Thespecificreasonsforusingthismetercouldnotbedetermined.
However,itisbelievedthatthiswasthelimitoftheavailable
technology
atthattime.Theonlyothermeteravailable
wasabasicdigitaltype,whichcouldnotbeusedduetotheinherently
slowresponseandupdatetime,causingagreateruncertainty
ofspecificsetpointvaluethantheanalogmeter.
Attachment
2toAEP:NRC:1125A
Page11(1)Corrective
ActionsandResultsAchievedZ&CnowusestheFlukeModel45digitalmeterduringtestingofthe4KVdieselstartand4KVESSbusundervoltage
relays.Recentdevelopments
indigitalmeterswhichincludefasterresponsetimesandupdatetimesandminimum/maximum
modifierfeatureshasmadetheiruseacceptable.
Thedigitalmetercurrently
beingusedhasanaccuracyof+0.3percent.Theprevioustestmethodprovidedacceptable
results,basedontheas-foundvaluesonthefirstuseofthedigitalmetersbeinginspecification
bycomparable
percentages.'2)
Corrective
ActionsTakenToAvoidFurtherViolation
Thecalibration
procedures
whichcurrently
allowuseofeitheranalogordigitalmeterswillbechangedtospecifytheuseoftheFlukeModel45digitalmeter,oritsequivalent,
toensureconsistent
useofadigitalmeter.(3)DateWhenFullComlieneeWillBeAchievedTheprocedure
changeswillbecompleted
beforeApril30,1990.
~~
Attachment
2toAEP:NRC:1125A
Page12NRC.Violation
4"10CFR50,AppendixB,Criterion
XVI,asimplemented
inSection1.7.16oftheDonaldC.CookOperational
QualityAssurance
Programrequiredthatmeasuresbeestablished
toassurethatconditions
adversetoqualitywerepromptlyidentified
andcorrected.
Inthecaseofsignificant
conditions
adversetoquality,themeasuresshallassurethatthecauseofthecondition
wasdetermined
andcorrective
actiontakentoprecluderepetition.
"Contrary
totheabove:ThePlantAssessment
GroupCommittee's
reviewinMarch1989forProblemReport89-245,concerned
withtheFebruary1989failureoftwosafety-related
4kVbreakersT-11D6andT-1104tocloseondemandduringtestsduetolubrication
hardening,
failedtospecifycorrective
actiontopreventrecurrence.
Furthermore,
noactionwastakentoinspectother4kVbreakersforcommonmodefailure.Consequently,
inMarchandAprilof1989sevenadditional
safetyrelatedandbalanceofplantbreakersfailedtocloseduringtesting,whichwasalsocausedbyhardening
ofthelubricant
onthebreakerlinkage(315/89031-04A;
316/89031-04A).
b.Corrective
actionwasneitherpromptnoradequatetocorrectmaintenance
related'roblems
identified
bythelicenseeinFebruary1988.InDecember1989,36ofthese71selfidentified
findingsandrecommendations
werereopened.
Duringthisinspection
manyofthesameproblemswereidentified
thatreflectasignificant
weaknessinthecorrective
actionsystem(315/89031-04B;
316/89031-04B)."
ResponsetoViolation
4aBasedonreviewofProblemReport89-245,whichwasaddressed
intheNoticeofViolation
itisourpositionthatnoactualviolation
occurred.
TheFebruary27,1989,condition
wasidentified
duringscheduled
'preventive
maintenance
workandresultedintheproblemreport.Thatdiscovery,
coupledwithasimilarcondition
alsofoundduringpreventive
maintenance,
resultedinaPart21report.ThePart21investigation
revealedthatvendor-specified
information
contained
noinstruction
forperiodiclubrication
ofthebreakers.
Similarbreakersusedintheplanthad,untilthattime,passedtestrequirements'he
plant'sactionswhichweretakenpromptly,
includedrevisionoftheprocedure
basedonnewinputfromthemanufacturer,
initiation
ofJobOrderstoinspectallothersimilarbreakersinstalled
inbothunits,andestablishment
ofscheduled
inspections
toidentifypossiblerepetition
ofthe
C.I1
Attachment
2toAEP:NRC:1125A
Page13condition
inthefuture.TheNoticeofViolation
incorrectly
concluded
thatnoactionwastakentoinspectadditional
breakersordevelopcorrective
action.Twosubsequent
problemreportswereinitiated
asaresultofdeficiencies
foundintheinspections
andtestscoveredbyourexpandedactionforProblemReport89-245andtheassociated
Part21review.Thosereportswereinitiated
todocumentthesimilarconditions
onthenotedbreakers.
WithintwomonthsoftheMarch1,1989,Part21reporttotheNRC,theplanthadcompleted
theinspections,
cleanedandrelubricated
thebreakersinbothunitsasrecommended
bytherevisedvendorinformation,
anddocumented
eachcasewhenasimilarcondition
wasfound.(1)Corrective
ActionTakenandResultsAchievedTheresultofProblemReport89-245,whichwasreviewedbythePlantAssessment
GrouponMarch17,1989,wastoinspect,cleanandlubricate
similarbreakersinbothunitsanddocumenttheresults.(2)Corrective
ActionTakentoAvoidFurtherViolation
Procedure
changesandinspections
werescheduled
asaresultofaddressing
theproblemreportedinProblemReport89-245onsimilarbreakers.
Theseactionsgenerated
additional
JobOrdersandcondition
reportswhichwerereferenced
intheinspection
report.(3)DateWhenFullComlianceWillBeAchievedNoviolation
occurred.
ResponsetoViolation
4bAsdiscussed
inourresponsetoWeakness(1),AEPhastakennumerouscorrective
actionstoaddresstheproblemsidentified
bytheMaintenance
Self-Assessment.
Theseactionsinclude:othedevelopment
ofaRCMProgramotheacquisition
oftheNuclearPlantMaintenance
(NPM)Moduleothedevelopment
ofaSystemEngineerProgramotheacquisition
ofNUS'sPRONETandtheservt.ces
ofNUS'sprocedure
writers.
Attachment
2toAEP:NRC:1125A
Page14Inordertoeffectively
implement
programsasencompassing
andcomprehensive
asthese,significant
analysis,
planningandcoordination
areneeded.Assuch,itwilltakeseveralyearstocompletely
implement
someofthecorrective
actionswehaveinitiated.
(1)Corrective
ActionsandResultsAchievedMaintenance-related
problemsidentified
intheMaintenance
Self-Assessment
willbereviewedandresolvedasappropriate,
withimplementation
oftheMaintenance
Improvement
Plan.(2)Corrective
ActionsTakentoAvoidFurtherViolation
TheImprovement
Planincludesmilestones
andabuilt-inmechanism
thatrequiresregularre-evaluation
oftheplanandmonitoring
ofitseffectiveness
toensurethatitisproviding
thedesiredresultsandthatthereiscontinuing
improvement
inallmaintenance-related
areas'3)DateWhenFullComlianceWillBeAchievedResolution
anddocumentation
oftheidentified
itemswillbecompleted
byJune1,1991.