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U. S. NUCLEAR REGULATORY COMMISSION
                                  U. S. NUCLEAR REGULATORY COMMISSION
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                                                REGION III
REGION III
                    Docket Nos: 50-454, 50-455                                             l
Docket Nos:
50-454, 50-455
l
License Nos: NPF-37, NPF-66
'
,
,
                    License Nos: NPF-37, NPF-66                                            '
i
i                    Report No:       50-454/96-07,50-455/96-07                               !
Report No:
50-454/96-07,50-455/96-07
Licensee:
Comed Company
-
-
                    Licensee:        Comed Company
1
1                                                                                            <
<
j                   Facility:         Byron Generating Station, Units 1 & 2                 '
j
.
Facility:
!                   Location:         Opus West III                                         ,
Byron Generating Station, Units 1 & 2
!                                       1400 Opus Place                                       l
'
.
!
Location:
Opus West III
,
!
1400 Opus Place
l
Downers Grove, IL 60515
4
4
                                      Downers Grove, IL 60515
a
a                                                                                             :
Dates:
                    Dates:           August 21 - September 26, 1996                         !
August 21 - September 26, 1996
:
:
'
Inspectors:
                    Inspectors:       S. D. Burgess, Senior Resident Inspector
S. D. Burgess, Senior Resident Inspector
                                      N. D. Hilton, Resident Inspector
'
N. D. Hilton, Resident Inspector
C. K. Thompson, Illinois Department of Nuclear Safety
,
,
                                      C. K. Thompson, Illinois Department of Nuclear Safety
Approved by:
                    Approved by:       Lewis F. Miller, Jr., Chief,
Lewis F. Miller, Jr., Chief,
.
.
                                        Division of Reactor Projects                         ;
Division of Reactor Projects
!
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!
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!
!
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4
1                                     .
1
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'I
'I
!
!
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                                              ~
~
      9610290199 961018                                                                       i
9610290199 961018
      POWt ADOCK CH5000454
i
      G                   PDR
POWt
ADOCK CH5000454
G
PDR


    . _ . _ . _             . _ . _ . ~   _ _ _ .         .   .--._._._ _ __ . . _ _ _ . _ _ _
. _ . _ . _
. _ . _ . ~
_ _ _ .
.
.--._._._ _
__ . . _ _ _ . _ _ _
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                                                                                                )
)
                                                  EXECUTIVE SUMARY
EXECUTIVE SUMARY
                                    Byron Generating Station, Units 1 & 2
Byron Generating Station, Units 1 & 2
                        NRC Inspection Report 50-454/96-007,50-455/96-007
NRC Inspection Report 50-454/96-007,50-455/96-007
  This inspection included aspects of licensee operations, engineering,                         l
This inspection included aspects of licensee operations, engineering,
  maintenance, and plant support. The report cover: a six week period of                       i
maintenance, and plant support. The report cover: a six week period of
  resic it inspection.
i
  DoeratLg_qi
resic it inspection.
  .        In general, the conduct of operations was professional and
DoeratLg_qi
          safety-conscious. The addition of a separate control room briefing for               !
In general, the conduct of operations was professional and
          maintenance, radiation protection, chemistry, and the extra operating shift         ;
.
          effectively eliminated personnel and outage activity distractions from the
safety-conscious. The addition of a separate control room briefing for
          main control room shift briefing (Section 01.1).                                     l
maintenance, radiation protection, chemistry, and the extra operating shift
  .        Operators responded promptly and effectively to a turbine trip and the               l
effectively eliminated personnel and outage activity distractions from the
          equipment failures subsequent to a resulting reactor trip (Section 01.2).           !
main control room shift briefing (Section 01.1).
  .        The inspectors identified a violation regarding inadequate procedures that
Operators responded promptly and effectively to a turbine trip and the
          resulted in running the 2A chemical and volume control pump without
.
          essential service water to the pump's lube oil cooler (Section 01.5).
equipment failures subsequent to a resulting reactor trip (Section 01.2).
  .        The inspectors identified poor heusekeeping in the 2A and 28 diesel oil             i
The inspectors identified a violation regarding inadequate procedures that
          storage tank rooms that resulted from fire protection system testing on
.
                                                                                                '
resulted in running the 2A chemical and volume control pump without
          July 22,1996 (Section 02.1).                                                         j
essential service water to the pump's lube oil cooler (Section 01.5).
  Maintenance
The inspectors identified poor heusekeeping in the 2A and 28 diesel oil
  .        Maintenance and surveillance activities were completed thoroughly and
.
          professionally with maintenance supervisors and system engineers monitoring
storage tank rooms that resulted from fire protection system testing on
          activities (Sections M1.1 and M1.2).
'
  Enaineerina
July 22,1996 (Section 02.1).
  .        Engineering department personnel provided sound and thorough safety
j
          evaluations regarding the Unit 2 steam generator (SG) A and SG C loose part
Maintenance
          retrieval plan and the evaluation of all four Unit 2 SG tube inspections
Maintenance and surveillance activities were completed thoroughly and
            (Section E2.1).
.
  Plant Support
professionally with maintenance supervisors and system engineers monitoring
  .        The inspectors noted good radiological controls and ALARA briefings in the
activities (Sections M1.1 and M1.2).
          Unit 2 refueling outage. Sound radiological protection controls and
Enaineerina
          careful radiological work practices were also noted during the performance
Engineering department personnel provided sound and thorough safety
          of surveillances and maintenance activities (Section RI).
.
  .        The identification and confiscation of a .38 weapon and ammunition
evaluations regarding the Unit 2 steam generator (SG) A and SG C loose part
            indicated the licensee's search techniques were effective (Section S1.1)
retrieval plan and the evaluation of all four Unit 2 SG tube inspections
                                                          2
(Section E2.1).
Plant Support
The inspectors noted good radiological controls and ALARA briefings in the
.
Unit 2 refueling outage. Sound radiological protection controls and
careful radiological work practices were also noted during the performance
of surveillances and maintenance activities (Section RI).
The identification and confiscation of a .38 weapon and ammunition
.
indicated the licensee's search techniques were effective (Section S1.1)
2


                                                      _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
  ,
,
-
-
-
            -
REPORT DETAILS
                                      REPORT DETAILS
S- ry of Plant Status
    S- ry of Plant Status
Unit 1 operated at power levels up to 97 percent until September 11, 1996,
    Unit 1 operated at power levels up to 97 percent until September 11, 1996,
when a reactor trip occurred as a result of a turbine trip. The unit was
    when a reactor trip occurred as a result of a turbine trip. The unit was
returned to service at 6:48 a.m. on September 12, 1996. The unit has since
    returned to service at 6:48 a.m. on September 12, 1996. The unit has since
operated at power levels up to 97 percent.
    operated at power levels up to 97 percent.
Unit 2 was in a refueling outage (B2R06) during this entire inspection period.
    Unit 2 was in a refueling outage (B2R06) during this entire inspection period.           ]
]
                                        I. Operations
I. Operations
    01 Conduct of Operations                                                                   l
01 Conduct of Operations
    01.1 General Comments (71707)
01.1 General Comments (71707)
          Using Inspection Procedure 71707, the inspectors conducted frequent                 '
Using Inspection Procedure 71707, the inspectors conducted frequent
          reviews of ongoing plant operations. In general, the conduct of                   l
'
          operations was professional and safety-conscious. Early in the outage,             "
reviews of ongoing plant operations.
          the licensee implemented a new control room briefing format where
In general, the conduct of
          personnel from the extra operating shift, radiation protection,                     l
l
          chemistry, and maintenance were briefed separately in the shift
operations was professional and safety-conscious. Early in the outage,
          engineer's office. The main control room briefing only included the               i
"
          on-duty operators for both units. The inspectors noted that the new
the licensee implemented a new control room briefing format where
          briefing format significantly reduced the number of personnel in the
personnel from the extra operating shift, radiation protection,
          main control room and distractions from outage activities. Specific
l
          events and noteworthy observations are detailed in the sections below.
chemistry, and maintenance were briefed separately in the shift
    01.2 Unit 1 Reactor Trio as a Result of a Turbine Trio
engineer's office. The main control room briefing only included the
      a.   Inspection Scope (93702)
i
                                                                                              ,
on-duty operators for both units. The inspectors noted that the new
          On September 11, 1996, at 12:17 a.m. (CDT), a Unit I reactor trip
briefing format significantly reduced the number of personnel in the
          occurred due to a turbine trip. While performing a monthly turbine trip
main control room and distractions from outage activities. Specific
          surveillance, a non-licensed operator inadvertently placed an operating             ,
events and noteworthy observations are detailed in the sections below.
          tool on the manual turbine trip lever instead of the turbine trip bypass
01.2 Unit 1 Reactor Trio as a Result of a Turbine Trio
          lever as required. The operator realized the error; however, in                     j
a.
          attempting to remove the operating tool, the operator caused a manual               i
Inspection Scope (93702)
          turbine trip.                                                                     j
,
      b.   Observations and Findinas
On September 11, 1996, at 12:17 a.m. (CDT), a Unit I reactor trip
          All safety related equipment automatically actuated as designed.
occurred due to a turbine trip. While performing a monthly turbine trip
          Channel A of the digital rod position indication (DRPI) failed during
surveillance, a non-licensed operator inadvertently placed an operating
          the trip; however, channel B indicated all rods were fully inserted.
,
          Other non-safety equipment failures during the transient included nine
tool on the manual turbine trip lever instead of the turbine trip bypass
          failed open feedwater (FW) heater relief valves, and the starting of the
lever as required. The operator realized the error; however, in
          startup FW pump due to a breaker failure.
j
                                              3
attempting to remove the operating tool, the operator caused a manual
i
turbine trip.
j
b.
Observations and Findinas
All safety related equipment automatically actuated as designed.
Channel A of the digital rod position indication (DRPI) failed during
the trip; however, channel B indicated all rods were fully inserted.
Other non-safety equipment failures during the transient included nine
failed open feedwater (FW) heater relief valves, and the starting of the
startup FW pump due to a breaker failure.
3


,
,
    _ _ _ . _ . _ _ _ . _ . _ . . _                 _ _ _ _ . . _ __ __ _.__-_ _ ____ _ _ ___                   _ _ _ ,
_ _ _ ,
                    ,
_ _ _ . _ . _ _ _ . _ . _ . . _
    '
_ _ _ _ . . _ __ __ _.__-_ _ ____ _ _ ___
                                                                                                                          l
,
                                                                                                                          l
'
.
.
                                      DRPI troubleshooting showed that there was a reduced coil voltage for a
DRPI troubleshooting showed that there was a reduced coil voltage for a
,                                    single coil on the A train coil stack for two rods. . The reduced voltage
single coil on the A train coil stack for two rods. . The reduced voltage
:                                     caused DRPI to spuriously misinterpret the location of the rod cluster
,
  '
:
                                      control assembly for A train only. This in turn caused DRPI urgent
caused DRPI to spuriously misinterpret the location of the rod cluster
,                                      failure and DRPI alarms. As interim corrective action, the licensee
control assembly for A train only. This in turn caused DRPI urgent
                                      removed several cards in the A train, which disabled that train for the
'
                                      two rods. Train B still provided indication for the operators.     Final
failure and DRPI alarms. As interim corrective action, the licensee
                                      problem resolution requires the plant to be shut down and the integrated
,
j                                     head package partially disassembled. This repair will be completed
removed several cards in the A train, which disabled that train for the
                                      during an outage of appropriate duration.
two rods. Train B still provided indication for the operators.
Final
problem resolution requires the plant to be shut down and the integrated
j
head package partially disassembled. This repair will be completed
.'
.'
:                                     The feedwater heater relief valves, installed as thermal relief valves,
during an outage of appropriate duration.
                                      experienced severe service and failed during the pressure increase
:
                                      accompanying main feedwater isolation following the_ turbine trip. The
The feedwater heater relief valves, installed as thermal relief valves,
                                      licensee's engineering department had been pursuing a potential
experienced severe service and failed during the pressure increase
  :
accompanying main feedwater isolation following the_ turbine trip. The
                                      modification to alleviate the lifting and damaging of the FW heater
licensee's engineering department had been pursuing a potential
:
modification to alleviate the lifting and damaging of the FW heater
;
;
'
relief valves. The nine FW relief valves were replaced prior to unit
                                      relief valves. The nine FW relief valves were replaced prior to unit
'
                                      startup. The startup FW pump breaker failure was due to the roller and
startup. The startup FW pump breaker failure was due to the roller and
can mechanism failing to latch. The breaker was replaced. As
,
,
                                      can mechanism failing to latch. The breaker was replaced. As
:
:                                      corrective action for the turbine trip, the licensee placed a barrier
corrective action for the turbine trip, the licensee placed a barrier
-
over the hub of the turbine trip lever to physically prevent the
                                      over the hub of the turbine trip lever to physically prevent the
-
                                      operating tool from fitting on the lever.
operating tool from fitting on the lever.
.
.
!                               01.3 Unit 1 Startuo Observations 0 1707)
!
01.3 Unit 1 Startuo Observations 0 1707)
)
)
The inspectors observed startup activities in the Unit I control room on
'
'
                                      The inspectors observed startup activities in the Unit I control room on
September 12, 1996. The startup was characterized by clear operator
                                      September 12, 1996. The startup was characterized by clear operator
i
i                                     communications, attentive reactor engineering oversight, and effective
communications, attentive reactor engineering oversight, and effective
control by shift supervision. A shift turnover near the point of
;
,
criticality was well-planned and controlled. The inspectors concluded
j
that the overall startup was performed effectively.
:
01.4 Both Source Ranae Monitors Out of Service
,
,
                                      control by shift supervision. A shift turnover near the point of                  ;
a.
                                      criticality was well-planned and controlled. The inspectors concluded
Inspection Scone (93702)
j                                      that the overall startup was performed effectively.
:                              01.4 Both Source Ranae Monitors Out of Service                                            ,
                                    a. Inspection Scone (93702)
i
i
The inspectors reviewed the licensee's actions in identifying both Unit
'
'
                                      The inspectors reviewed the licensee's actions in identifying both Unit
2 source range monitors out of service (00S).
                                      2 source range monitors out of service (00S).
>
>
i                                   b. Observations and Findinas
i
                                      On September 22, 1996, in Mode 5, the licensee identified that both               .
b.
Observations and Findinas
On September 22, 1996, in Mode 5, the licensee identified that both
.
'
'
                                      source range (SR) detectors were 00S for approximately 18 minutes during
source range (SR) detectors were 00S for approximately 18 minutes during
                                                                                                                          '
'
                                      surveillance testing. The SR detector N32 Level' Trip Bypass switch and           1
surveillance testing. The SR detector N32 Level' Trip Bypass switch and
j                                     the High Flux At Shutdown alarm were blocked during the performance of             l
1
4                                      surveillance 2BOS 3.1.1-21, " Train B Solid State Protection System
j
!                                     Bi-Monthly Surveillance," due to excessive detector spiking. At the
the High Flux At Shutdown alarm were blocked during the performance of
                                      time, N32 was considered inoperable as it was de-energized to perform
surveillance 2BOS 3.1.1-21, " Train B Solid State Protection System
i                                     the surveillance test. When the test for B train was completed, N32 was
4
j                                     left blocked due to continued excessive spiking and placed on the
!
                                                                                                                          \
Bi-Monthly Surveillance," due to excessive detector spiking. At the
time, N32 was considered inoperable as it was de-energized to perform
i
the surveillance test. When the test for B train was completed, N32 was
j
left blocked due to continued excessive spiking and placed on the
\\
;
;
I
I
.'
.'
.                                                                                               4
4
                                    __                            _                            -   - .
.
-
- .


  .
.
.
                                                                                      l
.
                                                                                      ,
l
          degraded equipment list. N32 was considered operable, because the
,
          spiking did not preclude count rate trending, could input to the boron
degraded equipment list. N32 was considered operable, because the
          dilution prevention system, and the reactor trip breakers were open.
spiking did not preclude count rate trending, could input to the boron
          The licensee identified that a shift change occurred without an apparent
dilution prevention system, and the reactor trip breakers were open.
          turnover on the status of SR detector N32. The new shift performed
The licensee identified that a shift change occurred without an apparent
          surveillance 2BOS 3.1.1-20, " Train A Solid State Protection System
turnover on the status of SR detector N32. The new shift performed
          Bi-Monthly Surveillance." During the train A surveillance, SR N31 was
surveillance 2BOS 3.1.1-20, " Train A Solid State Protection System
          inoperable due to being de-energized, the reactor trip breakers were
Bi-Monthly Surveillance." During the train A surveillance, SR N31 was
          closed, and SR detector N32 High Flux Level trip was in bypass. The         I
inoperable due to being de-energized, the reactor trip breakers were
          test lasted approximately 18 minutes, after which the reactor trip           I
closed, and SR detector N32 High Flux Level trip was in bypass. The
          breakers were open and SR detector N31 was energized and returned to         l
I
          service.                                                                     '
test lasted approximately 18 minutes, after which the reactor trip
          Technical Specification (TS) 3/4.3.1, Table 3.3-1, identified two           ,
breakers were open and SR detector N31 was energized and returned to
          shutdown conditions for which requirements were given for SR detector       I
service.
          operability: (1) the reactor trip breakers closed and the control rod
'
          drive system (CRDS) capable of rod withdrawal, or (2) the reactor trip
Technical Specification (TS) 3/4.3.1, Table 3.3-1, identified two
          breakers open. During the train A surveillance, the CRDS was disabled
,
          such that rod withdrawal was not possible and the reactor trip breakers
shutdown conditions for which requirements were given for SR detector
          were closed. Therefore, the plant was in a configuration where no TS
I
          action was required. However, TS interpretation 3/4.3.3.1-2, written by
operability:
          the licensee to cover this configuration, stated to default to the TS
(1) the reactor trip breakers closed and the control rod
          actions required in (1), and considered both SR monitors 00S. The
drive system (CRDS) capable of rod withdrawal, or (2) the reactor trip
          licensee stated that the TS interpretation was inappropriate and that
breakers open. During the train A surveillance, the CRDS was disabled
          the TS was satisfied, in that, the plant was in a configuration not
such that rod withdrawal was not possible and the reactor trip breakers
          covered by TS. The issue regarding the authority of TS interpretations
were closed. Therefore, the plant was in a configuration where no TS
          is considered an inspector follow-up item (50-455/96007-01(DRP)).
action was required. However, TS interpretation 3/4.3.3.1-2, written by
    01.5 Inadeauate Coolina to Chemical and Volume Control Pumn Lube Oil Cooler
the licensee to cover this configuration, stated to default to the TS
                                                                              '
actions required in (1), and considered both SR monitors 00S. The
      a.   Inspection Scope (71707)
licensee stated that the TS interpretation was inappropriate and that
          The inspectors reviewed a test where the 2A chemical and volume control
the TS was satisfied, in that, the plant was in a configuration not
          (CV) pump was run without essential service water cooling to the pump
covered by TS. The issue regarding the authority of TS interpretations
          lube oil cooler for 27 minutes.
is considered an inspector follow-up item (50-455/96007-01(DRP)).
      b.   Observations and Findt.ngi
01.5 Inadeauate Coolina to Chemical and Volume Control Pumn Lube Oil Cooler
          On September 14, 1996, the licensee identified that surveillance
'
          procedure 2BVS 1.2 3.1-1, "ASME Surveillance Requirements for
a.
          Centrifugal Chargir.g Pump 2A and Chemical and Volume Control System
Inspection Scope (71707)
          Valve Stroke Test,' kevision 12, was performed with essential service
The inspectors reviewed a test where the 2A chemical and volume control
          water (SX) isolated to the CV pump lube oil cooler for 27 minutes. The
(CV) pump was run without essential service water cooling to the pump
          discovery was made approximately five hours after the surveillance was
lube oil cooler for 27 minutes.
          completed.                                                                   '
b.
          The inspector identified that procedure 2BVS 1.2.3.1-1, failed to
Observations and Findt.ngi
          provide adequate steps to ensure that SX provided cooling to the 2A CV
On September 14, 1996, the licensee identified that surveillance
          pump lube oil cooler. This is considered a violation of 10 CFR 50,
procedure 2BVS 1.2 3.1-1, "ASME Surveillance Requirements for
          Appendix B, Criterion V (50-455/96007-02(DRP)).
Centrifugal Chargir.g Pump 2A and Chemical and Volume Control System
                                                                                        ,
Valve Stroke Test,' kevision 12, was performed with essential service
                                              5
water (SX) isolated to the CV pump lube oil cooler for 27 minutes. The
                                                                                  - .
discovery was made approximately five hours after the surveillance was
completed.
'
The inspector identified that procedure 2BVS 1.2.3.1-1, failed to
provide adequate steps to ensure that SX provided cooling to the 2A CV
pump lube oil cooler. This is considered a violation of 10 CFR 50,
Appendix B, Criterion V (50-455/96007-02(DRP)).
5
,
-
.


  .
.
.
          The licensee addressed the effects of having SX isolated to the 2A CV
.
          lube oil cooler for 27 minutes. The inspectors reviewed the point
The licensee addressed the effects of having SX isolated to the 2A CV
          history for the 2A CV pump which revealed that the bearing temperatures
lube oil cooler for 27 minutes. The inspectors reviewed the point
          were within the ASME surveillance requirements.
history for the 2A CV pump which revealed that the bearing temperatures
      c. Conclusions on the Conduct of Operations
were within the ASME surveillance requirements.
          Operators responded promptly and effectively to the turbine trip and to   i
c. Conclusions on the Conduct of Operations
          the equipment failures subsequent to the reactor trip. The inspectors
Operators responded promptly and effectively to the turbine trip and to
          determined that the licensee's short and long term corrective action for
i
          equipment failures experienced after the reactor trip were appropriate.
the equipment failures subsequent to the reactor trip.
          The inspectors identified concerns with configuration controls during
The inspectors
          the conduct of surveillance tests. In one instance, the inspectors       ;
determined that the licensee's short and long term corrective action for
          identified an inadequate procedure that resulted in the 2A CV pump being '
equipment failures experienced after the reactor trip were appropriate.
          run without essential water to the lube oil cooler. In the other
The inspectors identified concerns with configuration controls during
          instance, the lack of a thorough shift turnover resulted in both SR
the conduct of surveillance tests.
          monitors being 00S.
In one instance, the inspectors
    02 Operational Status of Facilities and Equipment
;
    02.1 Enaineered Safety Feature (ESF) System Walkdowns (71707)
identified an inadequate procedure that resulted in the 2A CV pump being
          The inspectors used Inspection Procedure 71707 to walk down accessible     <
'
          portions of the following ESF systems:                                   I
run without essential water to the lube oil cooler.
                                                                                    i
In the other
          .  Unit 2 Emergency Diesel Generators A & B                             I
instance, the lack of a thorough shift turnover resulted in both SR
                                                                                    l
monitors being 00S.
          Equipment operability, material condition, and housekeeping were         l
02 Operational Status of Facilities and Equipment
          acceptable except in the diesel oil storage tank rooms. The inspectors   l
02.1 Enaineered Safety Feature (ESF) System Walkdowns (71707)
          nMed that valve 2D0003D, the 2D diesel oil transfer pump discharge
The inspectors used Inspection Procedure 71707 to walk down accessible
          check valve, was not labelled. They also noted a large amount of dried
<
          fire suppression foam on several fire nozzles in the 2A and 2B diesel
portions of the following ESF systems:
          oil storage tank rooms, the floor, and some equipment. The fire
i
          protection system engineer stated to the inspectors that the foam was
Unit 2 Emergency Diesel Generators A & B
          residue from a once-every-three-year surveillance of the foam spray
.
          headers and deluge nozzles. This test was conducted on July 22, 1996.
Equipment operability, material condition, and housekeeping were
          The inspectors concluded that the two month delay in cleaning up the
acceptable except in the diesel oil storage tank rooms. The inspectors
          residue was an example of poor housekeeping. The licensee initiated
nMed that valve 2D0003D, the 2D diesel oil transfer pump discharge
          corrective actions to label the valve and clean the rooms. The
check valve, was not labelled. They also noted a large amount of dried
          inspectors had no further concerns.
fire suppression foam on several fire nozzles in the 2A and 2B diesel
    08     Miscellaneous Operations Issues (92901)
oil storage tank rooms, the floor, and some equipment. The fire
    08.1   (Closed) Violation 50-454/455-05013-03:   Inadequate procedures for
protection system engineer stated to the inspectors that the foam was
          the boric acid and diesel oil transfer systems. The inspectors
residue from a once-every-three-year surveillance of the foam spray
          reviewed the corrective actions as described in a letter from the       i
headers and deluge nozzles. This test was conducted on July 22, 1996.
          licensee dated April 17, 1996. The actions appeared adequate.             l
The inspectors concluded that the two month delay in cleaning up the
          However, the inspectors noted that there were minor                     j
residue was an example of poor housekeeping. The licensee initiated
          inconsistencies between procedures 2BVS 0.5-3.DO.1, " Unit 2 ASME       i
corrective actions to label the valve and clean the rooms. The
          Requirement for Test of the Diesel Oil Transfer System," Revision         i
inspectors had no further concerns.
                                                                                    !
08
                                            6
Miscellaneous Operations Issues (92901)
08.1
(Closed) Violation 50-454/455-05013-03:
Inadequate procedures for
the boric acid and diesel oil transfer systems. The inspectors
reviewed the corrective actions as described in a letter from the
i
licensee dated April 17, 1996. The actions appeared adequate.
However, the inspectors noted that there were minor
j
inconsistencies between procedures 2BVS 0.5-3.DO.1, " Unit 2 ASME
i
Requirement for Test of the Diesel Oil Transfer System," Revision
i
6


  .
.
.
    M1.2 Surveillance Observations
.
    a.   Inspection Scone (61726)
M1.2 Surveillance Observations
        The inspectors observed all or parts of the following surveillance and
a.
        special test procedures:
Inspection Scone (61726)
        . IBVS 0.5-3.CC.1-1       Surveillance Requirements for Component Cooling
The inspectors observed all or parts of the following surveillance and
                                    (CC) Pump ICC01PA
special test procedures:
            2BVS 8.2.1.2.E-2       125V Battery Bank 5-Year Capacity Test
. IBVS 0.5-3.CC.1-1
            2BVS 8.1.1.2.f-14     2B Diesel Generator Sequencer Test
Surveillance Requirements for Component Cooling
          . IBVS 1.2.3.1-2         ASME Surveillance Requirements for Centrifugal
(CC) Pump ICC01PA
                                    Charging (CV) Pump IB and Chemical Volume
2BVS 8.2.1.2.E-2
                                    Control System Valve Stroke Test
125V Battery Bank 5-Year Capacity Test
          . IBVS 5.2.f.3-1         ASME Surveillance Requirements for Residual Heat
2BVS 8.1.1.2.f-14
                                    Removal (RH) Pump 1RH01PA
2B Diesel Generator Sequencer Test
          . SPP 96-055             Dual Train Auxiliary Feedwater Suction Transient
. IBVS 1.2.3.1-2
                                    Hydraulic Test
ASME Surveillance Requirements for Centrifugal
      b. Observations and Findinas
Charging (CV) Pump IB and Chemical Volume
        During the observation of surveillances, the inspectors questioned the
Control System Valve Stroke Test
          use of a dedicated non-licensed operator to reposition manual valves
. IBVS 5.2.f.3-1
        when systems / trains were not considered out of service during the test.
ASME Surveillance Requirements for Residual Heat
        The licensee stated that the use of dedicated operators was utilized for
Removal (RH) Pump 1RH01PA
          systems that do not receive an automatic actuation.
. SPP 96-055
        The inspectors reviewed Byron operating procedure B0P RH-5, "RH System
Dual Train Auxiliary Feedwater Suction Transient
          Startup for Recirculation," Revision 9. The procedure noted that, in
Hydraulic Test
        Mode 4, the normally locked-closed RH recirculation to reactor water
b. Observations and Findinas
          storage tank isolation valve, RH8735, may be opened provided that a
During the observation of surveillances, the inspectors questioned the
          dedicated operator stationed nearby will close the valve in the event of
use of a dedicated non-licensed operator to reposition manual valves
          a safeguards actuation to ensure adequate flow is available to all four   !
when systems / trains were not considered out of service during the test.
          cold legs. The inspectors were concerned that the dependance of the       l
The licensee stated that the use of dedicated operators was utilized for
          operator created two new failure mechanisms: (1) the failure of the
systems that do not receive an automatic actuation.
          operator to close the valve, and (2) the failure of the valve to close.
The inspectors reviewed Byron operating procedure B0P RH-5, "RH System
          The inspectors discussed this issue with the NRC technical staff and
Startup for Recirculation," Revision 9.
          determined that the use of the dedicated operator was not an unreviewed
The procedure noted that, in
          safety questions since the bases for TS 3/4.5.3, ECCS Subsystems - T,,, <
Mode 4, the normally locked-closed RH recirculation to reactor water
          350'F, allowed one operable ECCS subsystem without single failure
storage tank isolation valve, RH8735, may be opened provided that a
          consideration in Mode 4 on the basis of the stable reactor reactivity
dedicated operator stationed nearby will close the valve in the event of
          condition and the limited core cooling requirements. The inspectors had
a safeguards actuation to ensure adequate flow is available to all four
          no further concerns with the use of dedicated operators for performance
cold legs. The inspectors were concerned that the dependance of the
          of this procedure.
operator created two new failure mechanisms:
    M1.5 Conclusions on Conduct of Maintenance and Surveillances
(1) the failure of the
                                                                                    1
operator to close the valve, and (2) the failure of the valve to close.
          Maintenance and surveillance activities were completed thoroughly and
The inspectors discussed this issue with the NRC technical staff and
          professionally with maintenance supervisors and system engineers
determined that the use of the dedicated operator was not an unreviewed
          monitoring activities.
safety questions since the bases for TS 3/4.5.3, ECCS Subsystems - T,,, <
                                                                                    ;
350'F, allowed one operable ECCS subsystem without single failure
                                              8
consideration in Mode 4 on the basis of the stable reactor reactivity
condition and the limited core cooling requirements. The inspectors had
no further concerns with the use of dedicated operators for performance
of this procedure.
M1.5 Conclusions on Conduct of Maintenance and Surveillances
Maintenance and surveillance activities were completed thoroughly and
professionally with maintenance supervisors and system engineers
monitoring activities.
;
8


                            -
-
,
,
  ,
,
                                                                                                                  l
~
                                                                                                                ~
                                                                                                                  l
!
!
;
;
                                                                                                                  i
i
i
                                                                  III. Encineerina
III. Encineerina
                                E2   Engineering Support of Facilities and Equipment                           )
E2
                                E2.1 Unit 2 Steam Generator Tube Leak & Tube Repair So-ary                       I
Engineering Support of Facilities and Equipment
                                    a. Inspection Scope (37551)                                                   l
E2.1 Unit 2 Steam Generator Tube Leak & Tube Repair So-ary
                                      The inspectors reviewed procedures and documents related to the Unit 2     I
a.
                                      steam generator (SG) A loose part retrieval and subsequent tube repairs.
Inspection Scope (37551)
                                      Also reviewed were the non-destructive examination results for all four
The inspectors reviewed procedures and documents related to the Unit 2
                                      Unit 2 SGs performed during B2R06 refueling outage.
steam generator (SG) A loose part retrieval and subsequent tube repairs.
                                    b. Observations and Findinas
Also reviewed were the non-destructive examination results for all four
                                                                                                                  i
Unit 2 SGs performed during B2R06 refueling outage.
                                      On August 9,1996, Byron Unit 2 was brought to cold shutdown due to a
b.
                                      primary-to-secondary leak in SG A. Byron engineering developed a           l
Observations and Findinas
                                      comprehensive plan to investigate the location, extent, and cause of the
i
                                      leak. The source of the leak was found to be in tube 16-110 located on
On August 9,1996, Byron Unit 2 was brought to cold shutdown due to a
                                      the cold leg side of SG A approximately one inch above the tube sheet.
primary-to-secondary leak in SG A.
                                      During eddy current examination, the licensee determined that the tube
Byron engineering developed a
                                      was damaged by a piece of metallic debris approximately 1-1/2" x 1" x
comprehensive plan to investigate the location, extent, and cause of the
                                      1/32" in size and triangular in shape. The loose part was retrieved and
leak. The source of the leak was found to be in tube 16-110 located on
                                      sent offsite for analysis. The licensee plugged four tubes in SG A as
the cold leg side of SG A approximately one inch above the tube sheet.
                                      corrective action. The licensee also retrieved a previously identified
During eddy current examination, the licensee determined that the tube
                                      loose part in SG C. The SG C loose part was identified as
was damaged by a piece of metallic debris approximately 1-1/2" x 1" x
                                      " wedge-shaped" metallic debris and was also sent offsite for further
1/32" in size and triangular in shape. The loose part was retrieved and
                                      analysis. The loose part was located in an area where the tubes were
sent offsite for analysis. The licensee plugged four tubes in SG A as
                                      plugged in previous outages. The part had not moved; therefore, no
corrective action. The licensee also retrieved a previously identified
                                      further tube plugging was necessary.
loose part in SG C.
                                      A total of 30 SG tubes were plugged during the Unit' 2 forced outage and   l
The SG C loose part was identified as
                                      the Unit 2 B2R06 refueling outage. All tubes were inspected from the
" wedge-shaped" metallic debris and was also sent offsite for further
                                      hot leg tube end to the cold leg tube end using a bobbin eddy current     ,
analysis. The loose part was located in an area where the tubes were
                                      inspection. Additional inspections included 25 percent top of tubesheet   i
plugged in previous outages. The part had not moved; therefore, no
                                      (hot leg) using the rotating pancake coil (RPC), 25 percent row I and
further tube plugging was necessary.
                                      row 2 U-Bend using Point Plus, and 25 percent preheater expansion region
A total of 30 SG tubes were plugged during the Unit' 2 forced outage and
                                      using RPC in SG A.
the Unit 2 B2R06 refueling outage. All tubes were inspected from the
                                                                                                                  i
hot leg tube end to the cold leg tube end using a bobbin eddy current
                                    c. Conclusions
,
                                                                                                                  !
inspection. Additional inspections included 25 percent top of tubesheet
                                      Engineering personnel made sound and thorough safety evaluations           ;
i
                                      regarding the Unit 2 SG A and SG C loose part retrieval plan and.         !
(hot leg) using the rotating pancake coil (RPC), 25 percent row I and
                                      evaluation and the evaluation of all four Unit 2 SG tube inspections.
row 2 U-Bend using Point Plus, and 25 percent preheater expansion region
                                                                                                                  1
using RPC in SG A.
                                E8    Miscellaneous Engineering Issues (92902)
i
                                                                                                                  i
c.
                                E8.1 (Closed) LER 50-455/96-003: Missed TS surveillance regarding SG tube       <
Conclusions
                                      inspections. On September 4,1996, the licensee identified that 26         I
Engineering personnel made sound and thorough safety evaluations
                                      tubes in SG D and 4 tubes in SG B were not inspected and analyzed in       '
;
                                      accordance with the original inspection plans for previous refueling
regarding the Unit 2 SG A and SG C loose part retrieval plan and.
                                      outages B2R03 and B2R05. The tubes were not inspected because they were
evaluation and the evaluation of all four Unit 2 SG tube inspections.
                                      misencoded with the wrong tube number. The licensee performed a review
E8
                                                                                9                                 I
Miscellaneous Engineering Issues (92902)
                                                                                                                  i
E8.1
                                                                                                                  i
(Closed) LER 50-455/96-003: Missed TS surveillance regarding SG tube
  .__ _ _ ____._______ _ __ .___                    _m          -       ..,-s   ,- - . - - . . ,__,
<
inspections. On September 4,1996, the licensee identified that 26
'
tubes in SG D and 4 tubes in SG B were not inspected and analyzed in
accordance with the original inspection plans for previous refueling
outages B2R03 and B2R05. The tubes were not inspected because they were
misencoded with the wrong tube number. The licensee performed a review
I
9
i
i
.
.
.
m
-
..,-s
,- - . - - . . ,__,


    . _ _ _ . __                 _ _ _ .     ___ . _ .. _ _ _ _ _ _ _ _                     _ _ _ _ _ , _ _
. _ _ _ . __
                '
_ _ _ .
  i
___ . _ .. _ _ _ _ _ _ _ _
1*
_ _ _ _ _ , _ _
'
i
1*
i
i
  I
I
                                                                                                              ,
,
j                       of previous and subsequent refuel outage tube inspections and determined
j
i                        that the 30 tubes contained no detectable degradation. The licensee's                '
of previous and subsequent refuel outage tube inspections and determined
;                        corrective actions were appropriate and the safety consequences were
;                        minor. This licensee identified and corrected violation is being
i
i
'
that the 30 tubes contained no detectable degradation. The licensee's
                        treated as a non-cited violation, consistent with Section VII.B.1 of the
'
                        NRC Enforcement Policy. This item is closed.                                         e
;
corrective actions were appropriate and the safety consequences were
;
minor. This licensee identified and corrected violation is being
i
treated as a non-cited violation, consistent with Section VII.B.1 of the
'
NRC Enforcement Policy. This item is closed.
e
)
)
1
1
                                                        IV. Plant Supoort
IV. Plant Supoort
                  R1   Radiological Protection and Chemistry (RP&C) Controls
R1
                        The inspectors noted good radiological controls implemented in the Unit
Radiological Protection and Chemistry (RP&C) Controls
                        2 refueling outage during frequent tours of the radiologically protected             ,
The inspectors noted good radiological controls implemented in the Unit
i                       area and ALARA briefings. The inspectors also noted sound radiological
2 refueling outage during frequent tours of the radiologically protected
v                       protection controls and careful radiological work practices during the
,
;                       surveillances and maintenance observations.
i
;                                                                                                             i
area and ALARA briefings. The inspectors also noted sound radiological
j                 R3   RP&C Procedures and Documentation                                                   i
v
                                                                                                              '
protection controls and careful radiological work practices during the
                  R3.1 Review of License Conditions
;
j                       The inspectors reviewed the license conditions and the TS administrative
surveillances and maintenance observations.
;                        controls section for discrepant conditions or practices. The inspectors
;
i                       identified minor discrepancies in section 6.12, "High Radiation Area"
i
j
R3
RP&C Procedures and Documentation
i
R3.1 Review of License Conditions
'
j
The inspectors reviewed the license conditions and the TS administrative
controls section for discrepant conditions or practices. The inspectors
;
i
identified minor discrepancies in section 6.12, "High Radiation Area"
!
and section 6.14, "Offsite Dose Calculation Manual (00CM)." Both
!
!
                        and section 6.14, "Offsite Dose Calculation Manual (00CM)." Both
sections had not been updated to reference the applicable sections of 10
!                        sections had not been updated to reference the applicable sections of 10
i
i                       CFR Part 20. Section 6.12 also defined the high radiation area dose                   l
CFR Part 20. Section 6.12 also defined the high radiation area dose
i                       equal to or less than 1000 mR/hr at 45 cm instead of 30 cm. 10 CFR Part
i
                        20.1008, " Implementation," states, in part, that the 10 CFR Part 20                 i
equal to or less than 1000 mR/hr at 45 cm instead of 30 cm.
:                       requirements must be used in lieu of the requirements that are cited in               l
10 CFR Part
l                       the licensee's TS. The inspectors confirmed that the licensee was in
20.1008, " Implementation," states, in part, that the 10 CFR Part 20
                        full compliance with the more restrictive requirements of 10 CFR Part
:
'
requirements must be used in lieu of the requirements that are cited in
i                        20. The licensee was already aware of the discrepancies and had made
l
j                       the necessary changes to their proposed Improved Technical
l
the licensee's TS. The inspectors confirmed that the licensee was in
'
full compliance with the more restrictive requirements of 10 CFR Part
i
20. The licensee was already aware of the discrepancies and had made
j
the necessary changes to their proposed Improved Technical
Specifications. The inspectors had no further concerns.
!
!
                        Specifications. The inspectors had no further concerns.
P1
                  P1    Conduct of Emergency Protection Activities
Conduct of Emergency Protection Activities
                  Pl.1 Yearly Emeraency Preparedness Meetina
Pl.1 Yearly Emeraency Preparedness Meetina
i
i
i
i                        On September 19, 1996, the inspectors attended the annual emergency
On September 19, 1996, the inspectors attended the annual emergency
!                       preparedness meeting. The meeting was attended by the licensee's
!
!                       station management, Comed corporate management, and state and local
preparedness meeting. The meeting was attended by the licensee's
!                       officials. The meeting presented the 1997 EP pians for Byron Station.
!
j                       The inspectors noted no concerns.
station management, Comed corporate management, and state and local
!
officials. The meeting presented the 1997 EP pians for Byron Station.
j
The inspectors noted no concerns.
S1
Conduct of Security and Safeguards Activities (11750)
4
4
                  S1    Conduct of Security and Safeguards Activities (11750)
j
j                  Sl.1 Identification and Confiscation of a Weapon
Sl.1
1                       On September 5,1996, a contractor attempted to bring a .38 caliber
Identification and Confiscation of a Weapon
j                       revolver, a speed loader, and 62 rounds of ammunition into the protected
1
On September 5,1996, a contractor attempted to bring a .38 caliber
j
revolver, a speed loader, and 62 rounds of ammunition into the protected
"
"
                                                                          10
10
:
:
:                                                                                                             ,
:
,
.
-
.
.
                                          -        .


    _ _ . _ _ _ _ _ _ _ _ _ _                         __           ___._ _ ___ _ _.             _ _ _ _ _       _m . _ _ _ _
_ _ . _ _ _ _ _ _ _ _ _ _
                              .
__
        *
___._ _ ___ _ _.
                                                                                          -
_ _ _ _ _
                                51   Conduct of Security and Safeguards Activities (71750)
_m
                                S1.1 Identification and Confiscation of a Weacon
. _ _ _ _
                                      On September 5, 1996, a contractor attempted to bring a .38 caliber
.
                                      revolver, a speed loader, and 62 rounds of ammunition into the protected
*
                                      area. The weapon and ammunition was identified during a lunchbox search
-
                                      after detecting a undefinable mass in the x-ray machine. Since the
51
                                      contractor did not have a permit for the weapon, the Ogle County                         l
Conduct of Security and Safeguards Activities (71750)
                                      authorities were notified.                                                               '
S1.1
                                                                                                                              1
Identification and Confiscation of a Weacon
                                      The licensee's investigation determined that the contractor did not have                 '
On September 5, 1996, a contractor attempted to bring a .38 caliber
                                      a harmful intent in bringing'the weapon into the protected area. The
revolver, a speed loader, and 62 rounds of ammunition into the protected
                                      individual had placed the weapon in the lunchbox after showing it
area. The weapon and ammunition was identified during a lunchbox search
                                      outside the owner controlled area the previous night and had forgotten
after detecting a undefinable mass in the x-ray machine.
                                      to remove it prior to entering the facility.
Since the
                                      Security implemented an aggressive program to improve search techniques
contractor did not have a permit for the weapon, the Ogle County
                                      as a result of recent SQV audit findings. The identification and
authorities were notified.
                                      confiscation of the weapon and ammunition indicated the program's
'
                                      effectiveness. The inspectors had no further concerns.
The licensee's investigation determined that the contractor did not have
                                F8   Miscellaneous Fire Protection Issues (92904)
'
                                F8.1 (closed) Violation 50-454/455/94020-01:             Failure to follow fire             -
a harmful intent in bringing'the weapon into the protected area. The
                                      protection procedure requiring tags be placed on fire doors that
individual had placed the weapon in the lunchbox after showing it
                                      were impaired. In August 1994, the inspectors identified two fire
outside the owner controlled area the previous night and had forgotten
                                                                                                                              ,
to remove it prior to entering the facility.
                                                                                                                              >
Security implemented an aggressive program to improve search techniques
                                      doors that were apparently impaired because the door sills had
as a result of recent SQV audit findings. The identification and
                                      been temporarily removed and two doors that were impaired by being                     ,
confiscation of the weapon and ammunition indicated the program's
                                      blocked opened. None of the doors were tagged as required by
effectiveness. The inspectors had no further concerns.
                                      procedure BAP 1100-3, " Fire Protection Systems, Fire Rated
F8
                                      Assemblies, Radiation, Ventilation, and Flood Seal Impairments."
Miscellaneous Fire Protection Issues (92904)
                                      The inspectors reviewed the licensee's corrective actions as
F8.1
                                      discussed in letters dated October 31, 1994, and March 15, 1996.
(closed) Violation 50-454/455/94020-01:
                                      The responses stated that the door sills were subsequently                             i
Failure to follow fire
                                      reinstalled, returning the doors to an unimpaired state. The
-
                                      responses also stated that the two blocked open fire doors were
protection procedure requiring tags be placed on fire doors that
                                      not considered impaired if personnel were nearby to close the
,
                                      doors in the event of a fire. However, the licensee acknowledged
were impaired.
                                      that BAP 1100-3 did nct specifically exempt tagging of impaired
In August 1994, the inspectors identified two fire
                                      fire doors if personnel were stationed nearby. As part of
>
                                      corrective action:,, fire marshall office personnel were counselled
doors that were apparently impaired because the door sills had
                                      on management expectations regarding procedure adherence. The
been temporarily removed and two doors that were impaired by being
                                      fire marshall also stated that fire door impairment requirements
,
                                      would be emphasized in annual station training and that procedure                       ,
blocked opened. None of the doors were tagged as required by
                                      BAP 1100-3 would be revised to clearly state the exemption.
procedure BAP 1100-3, " Fire Protection Systems, Fire Rated
1
Assemblies, Radiation, Ventilation, and Flood Seal Impairments."
'
The inspectors reviewed the licensee's corrective actions as
                                08.2 (Closed) Violation 50-454/455/95009-04: Failure to follow fire
discussed in letters dated October 31, 1994, and March 15, 1996.
                                      protection procedure requiring tags be placed on fire doors that
i
'
The responses stated that the door sills were subsequently
                                      were impaired. On September 18, 1995, the inspectors identified
reinstalled, returning the doors to an unimpaired state. The
responses also stated that the two blocked open fire doors were
not considered impaired if personnel were nearby to close the
doors in the event of a fire. However, the licensee acknowledged
that BAP 1100-3 did nct specifically exempt tagging of impaired
fire doors if personnel were stationed nearby. As part of
corrective action:,, fire marshall office personnel were counselled
on management expectations regarding procedure adherence. The
fire marshall also stated that fire door impairment requirements
would be emphasized in annual station training and that procedure
,
BAP 1100-3 would be revised to clearly state the exemption.
1
08.2 (Closed) Violation 50-454/455/95009-04:
Failure to follow fire
'
protection procedure requiring tags be placed on fire doors that
were impaired. On September 18, 1995, the inspectors identified
'
11
,
1
'
-
_-
-_
- _ -
-
,
,
                                                                                    11
1
  '
                                  -          _-  -_        - _ -                    -          ,


                                                -.-- ..       . . - . - - - -   - . - -
-.-- ..
    .
. . - . - - - -
  <
-
                                              .
. - -
      S1   Conduct of Security and Safeguards Activities (71750)
.
      S1.1 Identification and Confiscation of a Weapon
<
          On September 5,1996, a contractor attempted to bring a .38 caliber
.
          revolver, a speed loader, and 62 roud s of ammunition into the protected
S1
          area. The weapon and ammunition wa' Jentified during a lunchbox search
Conduct of Security and Safeguards Activities (71750)
          after detecting a undefinable mast . the x-ray machine. Since the
S1.1
          contractor did not have a permit i the weapon, the Ogle County
Identification and Confiscation of a Weapon
          authorities were notified.
On September 5,1996, a contractor attempted to bring a .38 caliber
          The licensee's investigation determined that the contractor did not have
revolver, a speed loader, and 62 roud s of ammunition into the protected
          a harmful intent in bringing the weapon into the protected area. The
area. The weapon and ammunition wa'
          individual had placed the weapon in the lunchbox after showing it
Jentified during a lunchbox search
          outside the owner controlled area the previous night and had forgotten
after detecting a undefinable mast
          to remove it prior to entering the facility.
. the x-ray machine.
          Security implemented an aggressive program to improve search techniques
Since the
          as a result of recent SQV audit findings.     The identification and
contractor did not have a permit
          confiscation of the weapon and ammunition indicated the program's
i the weapon, the Ogle County
          effectiveness. The inspectors had no further concerns.
authorities were notified.
      F8   Miscellaneous Fire Protection Issues (92904)
The licensee's investigation determined that the contractor did not have
      F8.1 (Closed) Violation 50-454/455/94020-01:       Failure to follow fire
a harmful intent in bringing the weapon into the protected area. The
          protection procedure requiring tags be placed on fire doors that
individual had placed the weapon in the lunchbox after showing it
          were impaired. In August 1994, the inspectors identified two fire
outside the owner controlled area the previous night and had forgotten
          doors that were apparently impaired because the door sills had                 l
to remove it prior to entering the facility.
          been temporarily removed and two doors that were impaired by being
Security implemented an aggressive program to improve search techniques
          blocked opened. None of the doors were tagged as required by
as a result of recent SQV audit findings.
          procedure BAP 1100-3, " Fire Protection Systems, Fire Rated
The identification and
          Assemblies, Radiation, Ventilation, and Flood Seal Impairments."
confiscation of the weapon and ammunition indicated the program's
          The inspectors reviewed the licensee's corrective actions as
effectiveness. The inspectors had no further concerns.
          discussed in letters dated October 31, 1994, and March 15, 1996.
F8
          The responses stated that the door sills were subsequently
Miscellaneous Fire Protection Issues (92904)
          reinstalled, returning the doors to an unimpaired state. The
F8.1
          responses also stated that the two blocked open fire doors were
(Closed) Violation 50-454/455/94020-01:
          not considered impaired if personnel were nearby to close the
Failure to follow fire
          doors in the event of a fire. However, the licensee acknowledged
protection procedure requiring tags be placed on fire doors that
          that BAP 1100-3 did not specifically exempt tagging of impaired
were impaired.
          fire doors if personnel were stationed nearby. As part of
In August 1994, the inspectors identified two fire
          corrective actions, fire marshall office personnel were counselled
doors that were apparently impaired because the door sills had
          on management expectations regarding procedure adherence. The
been temporarily removed and two doors that were impaired by being
          fire marshall also stated that fire door impairment requirements
blocked opened. None of the doors were tagged as required by
          would be emphasized in annual station training and that procedure
procedure BAP 1100-3, " Fire Protection Systems, Fire Rated
          BAP 1100-3 would be revised to clearly state the exemption.
Assemblies, Radiation, Ventilation, and Flood Seal Impairments."
                                              11
The inspectors reviewed the licensee's corrective actions as
discussed in letters dated October 31, 1994, and March 15, 1996.
The responses stated that the door sills were subsequently
reinstalled, returning the doors to an unimpaired state. The
responses also stated that the two blocked open fire doors were
not considered impaired if personnel were nearby to close the
doors in the event of a fire. However, the licensee acknowledged
that BAP 1100-3 did not specifically exempt tagging of impaired
fire doors if personnel were stationed nearby. As part of
corrective actions, fire marshall office personnel were counselled
on management expectations regarding procedure adherence. The
fire marshall also stated that fire door impairment requirements
would be emphasized in annual station training and that procedure
BAP 1100-3 would be revised to clearly state the exemption.
11
.
.


                                                                                !
1
=
=
                                                                                1
-
                    -
i
                                                                                i
08.2 (Closed) Violation 50-454/455/95009-04:
  08.2 (Closed) Violation 50-454/455/95009-04: Failure to follow fire           ,
Failure to follow fire
        protection procedure requiring tags be placed on fire doors that         I
,
        were impaired. On September 18, 1995, the inspectors identified         j
protection procedure requiring tags be placed on fire doors that
        two untagged fire doors that were blocked open during flushing of       '
were impaired. On September 18, 1995, the inspectors identified
        some floor drains. As discussed above, the violation occurred           i
j
        because of an inappropriate interpretation of procedure                 ,
two untagged fire doors that were blocked open during flushing of
        BAP 1100-3.                                                             l
'
        The inspector concluded that the fire door problems in 1994 and 1995   !
some floor drains. As discussed above, the violation occurred
        were isolated events and that adequate corrective actions had been       '
i
        taken. During the current inspection, the inspectors observed that
because of an inappropriate interpretation of procedure
        impaired fire doors were tagged as required.
,
                              V. Management Meetinas
BAP 1100-3.
  X1   Exit Meeting Summary
l
        The inspectors presented the inspection results to members of licensee
The inspector concluded that the fire door problems in 1994 and 1995
        management at the conclusion of the inspection on September 26, 1996.
were isolated events and that adequate corrective actions had been
        The inspectors asked the licensee whether any materials examined during
'
        the inspection should be considered proprietary. No proprietary
taken. During the current inspection, the inspectors observed that
        information was identified.
impaired fire doors were tagged as required.
                                                                                i
V. Management Meetinas
                                                                                !
X1
                          PARTIAL LIST OF PERSONS CONTACTED
Exit Meeting Summary
  Licensee
The inspectors presented the inspection results to members of licensee
  K. Graesser, Site Vice President
management at the conclusion of the inspection on September 26, 1996.
  K. Kofron, Station Manager
The inspectors asked the licensee whether any materials examined during
  D. Wozniak, Site Engineering Manager                                         ;
the inspection should be considered proprietary. No proprietary
  T. Gierich, Operations Manager
information was identified.
  P. Johnson, Technical Service Superintendent
i
  E. Campbell, Maintenance Superintendent
!
  M. Snow, Work Control Superintendent
PARTIAL LIST OF PERSONS CONTACTED
  D. Brindle, Regulatory Assurance Supervisor
Licensee
  K. Passmore, Station Support & Engineering Supervisor
K. Graesser, Site Vice President
  P. Donavin, Site Engineering Mod Design Supervisor
K. Kofron, Station Manager
  T. Schuster, Site Quality Verification Director
D. Wozniak, Site Engineering Manager
  R. Colglazier, NRC Coordinator
;
  B. Gossman, Chemistry Supervisor                                             ,
T. Gierich, Operations Manager
  S. Gackstetter, Thermal Group Leader                                         ,
P. Johnson, Technical Service Superintendent
  R. Wegner, Shift Operations Supervisor                                       :
E. Campbell, Maintenance Superintendent
  M. Rasmussen, Operations Engineer Unit 2                                     ;
M. Snow, Work Control Superintendent
  W. Kouba, Long Range Work Control Superintendent                             I
D. Brindle, Regulatory Assurance Supervisor
                                                                                ;
K. Passmore, Station Support & Engineering Supervisor
                                          12
P. Donavin, Site Engineering Mod Design Supervisor
                                                                                l
T. Schuster, Site Quality Verification Director
                                                                                1
R. Colglazier, NRC Coordinator
B. Gossman, Chemistry Supervisor
,
S. Gackstetter, Thermal Group Leader
,
R. Wegner, Shift Operations Supervisor
:
M. Rasmussen, Operations Engineer Unit 2
W. Kouba, Long Range Work Control Superintendent
I
;
12
1


    -   -   .       ..     . _ . .         .       .-       . .   -     .-
-
-
.
..
. _ . .
.
.-
. .
-
.-
.
.
          -
-
                            INSPECTION PROCEDURES USED
INSPECTION PROCEDURES USED
  IP 37551:   Onsite Engineering
IP 37551:
  IP 61726:   Surveillance Observations
Onsite Engineering
  IP 62703:   Maintenance Observations
IP 61726:
  IP 71707:   Plant Operations
Surveillance Observations
  IP 71750:   Plant Support Activities
IP 62703:
  IP 92901:   Followup - Plant Operations
Maintenance Observations
  IP 92902:   Followup - Engineering
IP 71707:
  IP 92903:   Followup - Maintenance
Plant Operations
  IP 92904:   Followup - Plant Support
IP 71750:
  IP 93702:   Prompt Onsite Response to Events at Operating Power Reactors
Plant Support Activities
                                                                              l
IP 92901:
                                                                              l
Followup - Plant Operations
                                                                              l
IP 92902:
                                          13
Followup - Engineering
IP 92903:
Followup - Maintenance
IP 92904:
Followup - Plant Support
IP 93702:
Prompt Onsite Response to Events at Operating Power Reactors
l
l
13


  _._       ._       __ .   _ . - _ _ _ _ _ _ . _ . _               ___._ _-         -   ._ _ . . . _ . _ . _ . _ _ _ _ - ~ _ _ _
_._
                                                                                                                    -
._
      .
__ .
_ . - _ _ _ _ _ _ . _ . _
___._ _-
-
._ _ . . . _ . _ . _ . _ _ _ _ - ~ _ _ _
-
.
;.
;.
.
.
                                    ITEMS OPENED, CLOSED, Alm DISCUSSED
ITEMS OPENED, CLOSED, Alm DISCUSSED
            Opened
Opened
,          50-455/96007-01         IFU                   Both Unit 2 source range monitors out of
50-455/96007-01
IFU
Both Unit 2 source range monitors out of
,
service.
'
'
                                                          service.
.
.
.
50-455/96007-02
'          50-455/96007-02         VIO                   Inadequate procedure regarding SX cooling to the
VIO
                                                          2A CV pump lube oil cooler,
Inadequate procedure regarding SX cooling to the
.'
2A CV pump lube oil cooler,
i
i
i
i          Closed
Closed
            50-454/455/95013-03     VIO                   Inadequate procedures for the boric acid and
50-454/455/95013-03
,                                                          diesel oil transfer systems,                                                       '
VIO
Inadequate procedures for the boric acid and
diesel oil transfer systems,
,
t
t
}           50-454/455-94010-01     IFI                   Weakness in the emergency operating procedure
'
.'                                                         verification and validation process.
}
50-454/455-94010-01
IFI
Weakness in the emergency operating procedure
.'
verification and validation process.
!
!
            50-454/96-017           LER                   Unit I trip due to personnel error during
50-454/96-017
LER
Unit I trip due to personnel error during
surveillance activities.
.
.
                                                          surveillance activities.
.
.
            50-455/96-003           LER                   Missed TS surveillance regarding SG tube
!.
!.                                                        . inspections.
50-455/96-003
            50-454/455/94020-01     VIO                   Failure to follow fire protection procedures..                                     >
LER
]           50-454/455/95009-04     VIO                   Failure to follow fire protection procedures,
Missed TS surveillance regarding SG tube
. inspections.
50-454/455/94020-01
VIO
Failure to follow fire protection procedures..
>
]
50-454/455/95009-04
VIO
Failure to follow fire protection procedures,
i
i
.                                                                                                                                             l
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d'
                                                                                                                                              '
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i                                                                                                                                             L
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                                                                                                                                              '
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                                                                                                                                            ,
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        ,.                                                                       _ . _ .   _         .,       ,_                     . ._
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                        _--- . _ _.   .-     -.       . . _ . . . - -. . - - .
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3
                                    LIST OF ACRONYMS USED
LIST OF ACRONYMS USED
      ALARA As Low As Reasonably Achievable
ALARA
      ASME American Society of Mechanical Engineers
As Low As Reasonably Achievable
      BOS   Byron Operating Procedure
ASME
American Society of Mechanical Engineers
BOS
Byron Operating Procedure
BVS
Byron Surveillance Procedure
'
CC
Component Cooling Water System
CRDS
Control Rod Drive System
CV
Chemical and Volume Control System
DRPI
Digital Rod Position Indication
'
'
      BVS  Byron Surveillance Procedure
ECCS
      CC    Component Cooling Water System
Emergency Core Cooling Systems
      CRDS  Control Rod Drive System
4
      CV    Chemical and Volume Control System
E0P
      DRPI  Digital Rod Position Indication
Emergency Operating Procedure
4'
ESF
      ECCS  Emergency Core Cooling Systems
Engineered Safety Feature
      E0P   Emergency Operating Procedure
'
'
      ESF  Engineered Safety Feature
FW
      FW    Feedwater System
Feedwater System
i     00S   Out of Service
i
      RH   Residual Heat Removal System
00S
      RPC   Rotating Pancake Coil
Out of Service
      SG   Steam Generator
RH
      SR   Source Range
Residual Heat Removal System
      SX   Essential Service Water
RPC
      TS   Technical Specification
Rotating Pancake Coil
      V&V   Verification and Validation
SG
Steam Generator
SR
Source Range
SX
Essential Service Water
TS
Technical Specification
V&V
Verification and Validation
;
;
:
:
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}}
}}

Latest revision as of 11:22, 12 December 2024

Insp Repts 50-454/96-07 & 50-455/96-07 on 960821-0926. Violations Noted.Major Areas Inspected:Operations, Maintenance,Engineering,Plant Support & Plant Status
ML20129F721
Person / Time
Site: Byron  
Issue date: 10/18/1996
From:
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20129F685 List:
References
50-454-96-07, 50-454-96-7, 50-455-96-07, 50-455-96-7, NUDOCS 9610290199
Download: ML20129F721 (15)


See also: IR 05000454/1996007

Text

.

. - .

. .

-_

. - - -

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.

<'

J

"

U. S. NUCLEAR REGULATORY COMMISSION

-

i

REGION III

Docket Nos:

50-454, 50-455

l

License Nos: NPF-37, NPF-66

'

,

i

Report No:

50-454/96-07,50-455/96-07

Licensee:

Comed Company

-

1

<

j

Facility:

Byron Generating Station, Units 1 & 2

'

.

!

Location:

Opus West III

,

!

1400 Opus Place

l

Downers Grove, IL 60515

4

a

Dates:

August 21 - September 26, 1996

Inspectors:

S. D. Burgess, Senior Resident Inspector

'

N. D. Hilton, Resident Inspector

C. K. Thompson, Illinois Department of Nuclear Safety

,

Approved by:

Lewis F. Miller, Jr., Chief,

.

Division of Reactor Projects

!

l

!

4

1

.

'I

!

.

~

9610290199 961018

i

POWt

ADOCK CH5000454

G

PDR

. _ . _ . _

. _ . _ . ~

_ _ _ .

.

.--._._._ _

__ . . _ _ _ . _ _ _

-

_

)

EXECUTIVE SUMARY

Byron Generating Station, Units 1 & 2

NRC Inspection Report 50-454/96-007,50-455/96-007

This inspection included aspects of licensee operations, engineering,

maintenance, and plant support. The report cover: a six week period of

i

resic it inspection.

DoeratLg_qi

In general, the conduct of operations was professional and

.

safety-conscious. The addition of a separate control room briefing for

maintenance, radiation protection, chemistry, and the extra operating shift

effectively eliminated personnel and outage activity distractions from the

main control room shift briefing (Section 01.1).

Operators responded promptly and effectively to a turbine trip and the

.

equipment failures subsequent to a resulting reactor trip (Section 01.2).

The inspectors identified a violation regarding inadequate procedures that

.

resulted in running the 2A chemical and volume control pump without

essential service water to the pump's lube oil cooler (Section 01.5).

The inspectors identified poor heusekeeping in the 2A and 28 diesel oil

.

storage tank rooms that resulted from fire protection system testing on

'

July 22,1996 (Section 02.1).

j

Maintenance

Maintenance and surveillance activities were completed thoroughly and

.

professionally with maintenance supervisors and system engineers monitoring

activities (Sections M1.1 and M1.2).

Enaineerina

Engineering department personnel provided sound and thorough safety

.

evaluations regarding the Unit 2 steam generator (SG) A and SG C loose part

retrieval plan and the evaluation of all four Unit 2 SG tube inspections

(Section E2.1).

Plant Support

The inspectors noted good radiological controls and ALARA briefings in the

.

Unit 2 refueling outage. Sound radiological protection controls and

careful radiological work practices were also noted during the performance

of surveillances and maintenance activities (Section RI).

The identification and confiscation of a .38 weapon and ammunition

.

indicated the licensee's search techniques were effective (Section S1.1)

2

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

,

-

-

REPORT DETAILS

S- ry of Plant Status

Unit 1 operated at power levels up to 97 percent until September 11, 1996,

when a reactor trip occurred as a result of a turbine trip. The unit was

returned to service at 6:48 a.m. on September 12, 1996. The unit has since

operated at power levels up to 97 percent.

Unit 2 was in a refueling outage (B2R06) during this entire inspection period.

]

I. Operations

01 Conduct of Operations

01.1 General Comments (71707)

Using Inspection Procedure 71707, the inspectors conducted frequent

'

reviews of ongoing plant operations.

In general, the conduct of

l

operations was professional and safety-conscious. Early in the outage,

"

the licensee implemented a new control room briefing format where

personnel from the extra operating shift, radiation protection,

l

chemistry, and maintenance were briefed separately in the shift

engineer's office. The main control room briefing only included the

i

on-duty operators for both units. The inspectors noted that the new

briefing format significantly reduced the number of personnel in the

main control room and distractions from outage activities. Specific

events and noteworthy observations are detailed in the sections below.

01.2 Unit 1 Reactor Trio as a Result of a Turbine Trio

a.

Inspection Scope (93702)

,

On September 11, 1996, at 12:17 a.m. (CDT), a Unit I reactor trip

occurred due to a turbine trip. While performing a monthly turbine trip

surveillance, a non-licensed operator inadvertently placed an operating

,

tool on the manual turbine trip lever instead of the turbine trip bypass

lever as required. The operator realized the error; however, in

j

attempting to remove the operating tool, the operator caused a manual

i

turbine trip.

j

b.

Observations and Findinas

All safety related equipment automatically actuated as designed.

Channel A of the digital rod position indication (DRPI) failed during

the trip; however, channel B indicated all rods were fully inserted.

Other non-safety equipment failures during the transient included nine

failed open feedwater (FW) heater relief valves, and the starting of the

startup FW pump due to a breaker failure.

3

,

_ _ _ ,

_ _ _ . _ . _ _ _ . _ . _ . . _

_ _ _ _ . . _ __ __ _.__-_ _ ____ _ _ ___

,

'

.

DRPI troubleshooting showed that there was a reduced coil voltage for a

single coil on the A train coil stack for two rods. . The reduced voltage

,

caused DRPI to spuriously misinterpret the location of the rod cluster

control assembly for A train only. This in turn caused DRPI urgent

'

failure and DRPI alarms. As interim corrective action, the licensee

,

removed several cards in the A train, which disabled that train for the

two rods. Train B still provided indication for the operators.

Final

problem resolution requires the plant to be shut down and the integrated

j

head package partially disassembled. This repair will be completed

.'

during an outage of appropriate duration.

The feedwater heater relief valves, installed as thermal relief valves,

experienced severe service and failed during the pressure increase

accompanying main feedwater isolation following the_ turbine trip. The

licensee's engineering department had been pursuing a potential

modification to alleviate the lifting and damaging of the FW heater

relief valves. The nine FW relief valves were replaced prior to unit

'

startup. The startup FW pump breaker failure was due to the roller and

can mechanism failing to latch. The breaker was replaced. As

,

corrective action for the turbine trip, the licensee placed a barrier

over the hub of the turbine trip lever to physically prevent the

-

operating tool from fitting on the lever.

.

!

01.3 Unit 1 Startuo Observations 0 1707)

)

The inspectors observed startup activities in the Unit I control room on

'

September 12, 1996. The startup was characterized by clear operator

i

communications, attentive reactor engineering oversight, and effective

control by shift supervision. A shift turnover near the point of

,

criticality was well-planned and controlled. The inspectors concluded

j

that the overall startup was performed effectively.

01.4 Both Source Ranae Monitors Out of Service

,

a.

Inspection Scone (93702)

i

The inspectors reviewed the licensee's actions in identifying both Unit

'

2 source range monitors out of service (00S).

>

i

b.

Observations and Findinas

On September 22, 1996, in Mode 5, the licensee identified that both

.

'

source range (SR) detectors were 00S for approximately 18 minutes during

'

surveillance testing. The SR detector N32 Level' Trip Bypass switch and

1

j

the High Flux At Shutdown alarm were blocked during the performance of

surveillance 2BOS 3.1.1-21, " Train B Solid State Protection System

4

!

Bi-Monthly Surveillance," due to excessive detector spiking. At the

time, N32 was considered inoperable as it was de-energized to perform

i

the surveillance test. When the test for B train was completed, N32 was

j

left blocked due to continued excessive spiking and placed on the

\\

I

.'

4

.

-

- .

.

.

l

,

degraded equipment list. N32 was considered operable, because the

spiking did not preclude count rate trending, could input to the boron

dilution prevention system, and the reactor trip breakers were open.

The licensee identified that a shift change occurred without an apparent

turnover on the status of SR detector N32. The new shift performed

surveillance 2BOS 3.1.1-20, " Train A Solid State Protection System

Bi-Monthly Surveillance." During the train A surveillance, SR N31 was

inoperable due to being de-energized, the reactor trip breakers were

closed, and SR detector N32 High Flux Level trip was in bypass. The

I

test lasted approximately 18 minutes, after which the reactor trip

breakers were open and SR detector N31 was energized and returned to

service.

'

Technical Specification (TS) 3/4.3.1, Table 3.3-1, identified two

,

shutdown conditions for which requirements were given for SR detector

I

operability:

(1) the reactor trip breakers closed and the control rod

drive system (CRDS) capable of rod withdrawal, or (2) the reactor trip

breakers open. During the train A surveillance, the CRDS was disabled

such that rod withdrawal was not possible and the reactor trip breakers

were closed. Therefore, the plant was in a configuration where no TS

action was required. However, TS interpretation 3/4.3.3.1-2, written by

the licensee to cover this configuration, stated to default to the TS

actions required in (1), and considered both SR monitors 00S. The

licensee stated that the TS interpretation was inappropriate and that

the TS was satisfied, in that, the plant was in a configuration not

covered by TS. The issue regarding the authority of TS interpretations

is considered an inspector follow-up item (50-455/96007-01(DRP)).

01.5 Inadeauate Coolina to Chemical and Volume Control Pumn Lube Oil Cooler

'

a.

Inspection Scope (71707)

The inspectors reviewed a test where the 2A chemical and volume control

(CV) pump was run without essential service water cooling to the pump

lube oil cooler for 27 minutes.

b.

Observations and Findt.ngi

On September 14, 1996, the licensee identified that surveillance

procedure 2BVS 1.2 3.1-1, "ASME Surveillance Requirements for

Centrifugal Chargir.g Pump 2A and Chemical and Volume Control System

Valve Stroke Test,' kevision 12, was performed with essential service

water (SX) isolated to the CV pump lube oil cooler for 27 minutes. The

discovery was made approximately five hours after the surveillance was

completed.

'

The inspector identified that procedure 2BVS 1.2.3.1-1, failed to

provide adequate steps to ensure that SX provided cooling to the 2A CV

pump lube oil cooler. This is considered a violation of 10 CFR 50,

Appendix B, Criterion V (50-455/96007-02(DRP)).

5

,

-

.

.

.

The licensee addressed the effects of having SX isolated to the 2A CV

lube oil cooler for 27 minutes. The inspectors reviewed the point

history for the 2A CV pump which revealed that the bearing temperatures

were within the ASME surveillance requirements.

c. Conclusions on the Conduct of Operations

Operators responded promptly and effectively to the turbine trip and to

i

the equipment failures subsequent to the reactor trip.

The inspectors

determined that the licensee's short and long term corrective action for

equipment failures experienced after the reactor trip were appropriate.

The inspectors identified concerns with configuration controls during

the conduct of surveillance tests.

In one instance, the inspectors

identified an inadequate procedure that resulted in the 2A CV pump being

'

run without essential water to the lube oil cooler.

In the other

instance, the lack of a thorough shift turnover resulted in both SR

monitors being 00S.

02 Operational Status of Facilities and Equipment

02.1 Enaineered Safety Feature (ESF) System Walkdowns (71707)

The inspectors used Inspection Procedure 71707 to walk down accessible

<

portions of the following ESF systems:

i

Unit 2 Emergency Diesel Generators A & B

.

Equipment operability, material condition, and housekeeping were

acceptable except in the diesel oil storage tank rooms. The inspectors

nMed that valve 2D0003D, the 2D diesel oil transfer pump discharge

check valve, was not labelled. They also noted a large amount of dried

fire suppression foam on several fire nozzles in the 2A and 2B diesel

oil storage tank rooms, the floor, and some equipment. The fire

protection system engineer stated to the inspectors that the foam was

residue from a once-every-three-year surveillance of the foam spray

headers and deluge nozzles. This test was conducted on July 22, 1996.

The inspectors concluded that the two month delay in cleaning up the

residue was an example of poor housekeeping. The licensee initiated

corrective actions to label the valve and clean the rooms. The

inspectors had no further concerns.

08

Miscellaneous Operations Issues (92901)

08.1

(Closed) Violation 50-454/455-05013-03:

Inadequate procedures for

the boric acid and diesel oil transfer systems. The inspectors

reviewed the corrective actions as described in a letter from the

i

licensee dated April 17, 1996. The actions appeared adequate.

However, the inspectors noted that there were minor

j

inconsistencies between procedures 2BVS 0.5-3.DO.1, " Unit 2 ASME

i

Requirement for Test of the Diesel Oil Transfer System," Revision

i

6

.

.

M1.2 Surveillance Observations

a.

Inspection Scone (61726)

The inspectors observed all or parts of the following surveillance and

special test procedures:

. IBVS 0.5-3.CC.1-1

Surveillance Requirements for Component Cooling

(CC) Pump ICC01PA

2BVS 8.2.1.2.E-2

125V Battery Bank 5-Year Capacity Test

2BVS 8.1.1.2.f-14

2B Diesel Generator Sequencer Test

. IBVS 1.2.3.1-2

ASME Surveillance Requirements for Centrifugal

Charging (CV) Pump IB and Chemical Volume

Control System Valve Stroke Test

. IBVS 5.2.f.3-1

ASME Surveillance Requirements for Residual Heat

Removal (RH) Pump 1RH01PA

. SPP 96-055

Dual Train Auxiliary Feedwater Suction Transient

Hydraulic Test

b. Observations and Findinas

During the observation of surveillances, the inspectors questioned the

use of a dedicated non-licensed operator to reposition manual valves

when systems / trains were not considered out of service during the test.

The licensee stated that the use of dedicated operators was utilized for

systems that do not receive an automatic actuation.

The inspectors reviewed Byron operating procedure B0P RH-5, "RH System

Startup for Recirculation," Revision 9.

The procedure noted that, in

Mode 4, the normally locked-closed RH recirculation to reactor water

storage tank isolation valve, RH8735, may be opened provided that a

dedicated operator stationed nearby will close the valve in the event of

a safeguards actuation to ensure adequate flow is available to all four

cold legs. The inspectors were concerned that the dependance of the

operator created two new failure mechanisms:

(1) the failure of the

operator to close the valve, and (2) the failure of the valve to close.

The inspectors discussed this issue with the NRC technical staff and

determined that the use of the dedicated operator was not an unreviewed

safety questions since the bases for TS 3/4.5.3, ECCS Subsystems - T,,, <

350'F, allowed one operable ECCS subsystem without single failure

consideration in Mode 4 on the basis of the stable reactor reactivity

condition and the limited core cooling requirements. The inspectors had

no further concerns with the use of dedicated operators for performance

of this procedure.

M1.5 Conclusions on Conduct of Maintenance and Surveillances

Maintenance and surveillance activities were completed thoroughly and

professionally with maintenance supervisors and system engineers

monitoring activities.

8

-

,

,

~

!

i

III. Encineerina

E2

Engineering Support of Facilities and Equipment

E2.1 Unit 2 Steam Generator Tube Leak & Tube Repair So-ary

a.

Inspection Scope (37551)

The inspectors reviewed procedures and documents related to the Unit 2

steam generator (SG) A loose part retrieval and subsequent tube repairs.

Also reviewed were the non-destructive examination results for all four

Unit 2 SGs performed during B2R06 refueling outage.

b.

Observations and Findinas

i

On August 9,1996, Byron Unit 2 was brought to cold shutdown due to a

primary-to-secondary leak in SG A.

Byron engineering developed a

comprehensive plan to investigate the location, extent, and cause of the

leak. The source of the leak was found to be in tube 16-110 located on

the cold leg side of SG A approximately one inch above the tube sheet.

During eddy current examination, the licensee determined that the tube

was damaged by a piece of metallic debris approximately 1-1/2" x 1" x

1/32" in size and triangular in shape. The loose part was retrieved and

sent offsite for analysis. The licensee plugged four tubes in SG A as

corrective action. The licensee also retrieved a previously identified

loose part in SG C.

The SG C loose part was identified as

" wedge-shaped" metallic debris and was also sent offsite for further

analysis. The loose part was located in an area where the tubes were

plugged in previous outages. The part had not moved; therefore, no

further tube plugging was necessary.

A total of 30 SG tubes were plugged during the Unit' 2 forced outage and

the Unit 2 B2R06 refueling outage. All tubes were inspected from the

hot leg tube end to the cold leg tube end using a bobbin eddy current

,

inspection. Additional inspections included 25 percent top of tubesheet

i

(hot leg) using the rotating pancake coil (RPC), 25 percent row I and

row 2 U-Bend using Point Plus, and 25 percent preheater expansion region

using RPC in SG A.

i

c.

Conclusions

Engineering personnel made sound and thorough safety evaluations

regarding the Unit 2 SG A and SG C loose part retrieval plan and.

evaluation and the evaluation of all four Unit 2 SG tube inspections.

E8

Miscellaneous Engineering Issues (92902)

E8.1

(Closed) LER 50-455/96-003: Missed TS surveillance regarding SG tube

<

inspections. On September 4,1996, the licensee identified that 26

'

tubes in SG D and 4 tubes in SG B were not inspected and analyzed in

accordance with the original inspection plans for previous refueling

outages B2R03 and B2R05. The tubes were not inspected because they were

misencoded with the wrong tube number. The licensee performed a review

I

9

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.

.

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,- - . - - . . ,__,

. _ _ _ . __

_ _ _ .

___ . _ .. _ _ _ _ _ _ _ _

_ _ _ _ _ , _ _

'

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1*

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,

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of previous and subsequent refuel outage tube inspections and determined

i

that the 30 tubes contained no detectable degradation. The licensee's

'

corrective actions were appropriate and the safety consequences were

minor. This licensee identified and corrected violation is being

i

treated as a non-cited violation, consistent with Section VII.B.1 of the

'

NRC Enforcement Policy. This item is closed.

e

)

1

IV. Plant Supoort

R1

Radiological Protection and Chemistry (RP&C) Controls

The inspectors noted good radiological controls implemented in the Unit

2 refueling outage during frequent tours of the radiologically protected

,

i

area and ALARA briefings. The inspectors also noted sound radiological

v

protection controls and careful radiological work practices during the

surveillances and maintenance observations.

i

j

R3

RP&C Procedures and Documentation

i

R3.1 Review of License Conditions

'

j

The inspectors reviewed the license conditions and the TS administrative

controls section for discrepant conditions or practices. The inspectors

i

identified minor discrepancies in section 6.12, "High Radiation Area"

!

and section 6.14, "Offsite Dose Calculation Manual (00CM)." Both

!

sections had not been updated to reference the applicable sections of 10

i

CFR Part 20. Section 6.12 also defined the high radiation area dose

i

equal to or less than 1000 mR/hr at 45 cm instead of 30 cm.

10 CFR Part 20.1008, " Implementation," states, in part, that the 10 CFR Part 20

requirements must be used in lieu of the requirements that are cited in

l

l

the licensee's TS. The inspectors confirmed that the licensee was in

'

full compliance with the more restrictive requirements of 10 CFR Part

i

20. The licensee was already aware of the discrepancies and had made

j

the necessary changes to their proposed Improved Technical

Specifications. The inspectors had no further concerns.

!

P1

Conduct of Emergency Protection Activities

Pl.1 Yearly Emeraency Preparedness Meetina

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On September 19, 1996, the inspectors attended the annual emergency

!

preparedness meeting. The meeting was attended by the licensee's

!

station management, Comed corporate management, and state and local

!

officials. The meeting presented the 1997 EP pians for Byron Station.

j

The inspectors noted no concerns.

S1

Conduct of Security and Safeguards Activities (11750)

4

j

Sl.1

Identification and Confiscation of a Weapon

1

On September 5,1996, a contractor attempted to bring a .38 caliber

j

revolver, a speed loader, and 62 rounds of ammunition into the protected

"

10

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.

-

.

_ _ . _ _ _ _ _ _ _ _ _ _

__

___._ _ ___ _ _.

_ _ _ _ _

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. _ _ _ _

.

-

51

Conduct of Security and Safeguards Activities (71750)

S1.1

Identification and Confiscation of a Weacon

On September 5, 1996, a contractor attempted to bring a .38 caliber

revolver, a speed loader, and 62 rounds of ammunition into the protected

area. The weapon and ammunition was identified during a lunchbox search

after detecting a undefinable mass in the x-ray machine.

Since the

contractor did not have a permit for the weapon, the Ogle County

authorities were notified.

'

The licensee's investigation determined that the contractor did not have

'

a harmful intent in bringing'the weapon into the protected area. The

individual had placed the weapon in the lunchbox after showing it

outside the owner controlled area the previous night and had forgotten

to remove it prior to entering the facility.

Security implemented an aggressive program to improve search techniques

as a result of recent SQV audit findings. The identification and

confiscation of the weapon and ammunition indicated the program's

effectiveness. The inspectors had no further concerns.

F8

Miscellaneous Fire Protection Issues (92904)

F8.1

(closed) Violation 50-454/455/94020-01:

Failure to follow fire

-

protection procedure requiring tags be placed on fire doors that

,

were impaired.

In August 1994, the inspectors identified two fire

>

doors that were apparently impaired because the door sills had

been temporarily removed and two doors that were impaired by being

,

blocked opened. None of the doors were tagged as required by

procedure BAP 1100-3, " Fire Protection Systems, Fire Rated

Assemblies, Radiation, Ventilation, and Flood Seal Impairments."

The inspectors reviewed the licensee's corrective actions as

discussed in letters dated October 31, 1994, and March 15, 1996.

i

The responses stated that the door sills were subsequently

reinstalled, returning the doors to an unimpaired state. The

responses also stated that the two blocked open fire doors were

not considered impaired if personnel were nearby to close the

doors in the event of a fire. However, the licensee acknowledged

that BAP 1100-3 did nct specifically exempt tagging of impaired

fire doors if personnel were stationed nearby. As part of

corrective action:,, fire marshall office personnel were counselled

on management expectations regarding procedure adherence. The

fire marshall also stated that fire door impairment requirements

would be emphasized in annual station training and that procedure

,

BAP 1100-3 would be revised to clearly state the exemption.

1

08.2 (Closed) Violation 50-454/455/95009-04:

Failure to follow fire

'

protection procedure requiring tags be placed on fire doors that

were impaired. On September 18, 1995, the inspectors identified

'

11

,

1

'

-

_-

-_

- _ -

-

,

-.-- ..

. . - . - - - -

-

. - -

.

<

.

S1

Conduct of Security and Safeguards Activities (71750)

S1.1

Identification and Confiscation of a Weapon

On September 5,1996, a contractor attempted to bring a .38 caliber

revolver, a speed loader, and 62 roud s of ammunition into the protected

area. The weapon and ammunition wa'

Jentified during a lunchbox search

after detecting a undefinable mast

. the x-ray machine.

Since the

contractor did not have a permit

i the weapon, the Ogle County

authorities were notified.

The licensee's investigation determined that the contractor did not have

a harmful intent in bringing the weapon into the protected area. The

individual had placed the weapon in the lunchbox after showing it

outside the owner controlled area the previous night and had forgotten

to remove it prior to entering the facility.

Security implemented an aggressive program to improve search techniques

as a result of recent SQV audit findings.

The identification and

confiscation of the weapon and ammunition indicated the program's

effectiveness. The inspectors had no further concerns.

F8

Miscellaneous Fire Protection Issues (92904)

F8.1

(Closed) Violation 50-454/455/94020-01:

Failure to follow fire

protection procedure requiring tags be placed on fire doors that

were impaired.

In August 1994, the inspectors identified two fire

doors that were apparently impaired because the door sills had

been temporarily removed and two doors that were impaired by being

blocked opened. None of the doors were tagged as required by

procedure BAP 1100-3, " Fire Protection Systems, Fire Rated

Assemblies, Radiation, Ventilation, and Flood Seal Impairments."

The inspectors reviewed the licensee's corrective actions as

discussed in letters dated October 31, 1994, and March 15, 1996.

The responses stated that the door sills were subsequently

reinstalled, returning the doors to an unimpaired state. The

responses also stated that the two blocked open fire doors were

not considered impaired if personnel were nearby to close the

doors in the event of a fire. However, the licensee acknowledged

that BAP 1100-3 did not specifically exempt tagging of impaired

fire doors if personnel were stationed nearby. As part of

corrective actions, fire marshall office personnel were counselled

on management expectations regarding procedure adherence. The

fire marshall also stated that fire door impairment requirements

would be emphasized in annual station training and that procedure

BAP 1100-3 would be revised to clearly state the exemption.

11

.

1

=

-

i

08.2 (Closed) Violation 50-454/455/95009-04:

Failure to follow fire

,

protection procedure requiring tags be placed on fire doors that

were impaired. On September 18, 1995, the inspectors identified

j

two untagged fire doors that were blocked open during flushing of

'

some floor drains. As discussed above, the violation occurred

i

because of an inappropriate interpretation of procedure

,

BAP 1100-3.

l

The inspector concluded that the fire door problems in 1994 and 1995

were isolated events and that adequate corrective actions had been

'

taken. During the current inspection, the inspectors observed that

impaired fire doors were tagged as required.

V. Management Meetinas

X1

Exit Meeting Summary

The inspectors presented the inspection results to members of licensee

management at the conclusion of the inspection on September 26, 1996.

The inspectors asked the licensee whether any materials examined during

the inspection should be considered proprietary. No proprietary

information was identified.

i

!

PARTIAL LIST OF PERSONS CONTACTED

Licensee

K. Graesser, Site Vice President

K. Kofron, Station Manager

D. Wozniak, Site Engineering Manager

T. Gierich, Operations Manager

P. Johnson, Technical Service Superintendent

E. Campbell, Maintenance Superintendent

M. Snow, Work Control Superintendent

D. Brindle, Regulatory Assurance Supervisor

K. Passmore, Station Support & Engineering Supervisor

P. Donavin, Site Engineering Mod Design Supervisor

T. Schuster, Site Quality Verification Director

R. Colglazier, NRC Coordinator

B. Gossman, Chemistry Supervisor

,

S. Gackstetter, Thermal Group Leader

,

R. Wegner, Shift Operations Supervisor

M. Rasmussen, Operations Engineer Unit 2

W. Kouba, Long Range Work Control Superintendent

I

12

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.-

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INSPECTION PROCEDURES USED

IP 37551:

Onsite Engineering

IP 61726:

Surveillance Observations

IP 62703:

Maintenance Observations

IP 71707:

Plant Operations

IP 71750:

Plant Support Activities

IP 92901:

Followup - Plant Operations

IP 92902:

Followup - Engineering

IP 92903:

Followup - Maintenance

IP 92904:

Followup - Plant Support

IP 93702:

Prompt Onsite Response to Events at Operating Power Reactors

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ITEMS OPENED, CLOSED, Alm DISCUSSED

Opened

50-455/96007-01

IFU

Both Unit 2 source range monitors out of

,

service.

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.

50-455/96007-02

VIO

Inadequate procedure regarding SX cooling to the

.'

2A CV pump lube oil cooler,

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Closed

50-454/455/95013-03

VIO

Inadequate procedures for the boric acid and

diesel oil transfer systems,

,

t

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50-454/455-94010-01

IFI

Weakness in the emergency operating procedure

.'

verification and validation process.

!

50-454/96-017

LER

Unit I trip due to personnel error during

surveillance activities.

.

.

!.

50-455/96-003

LER

Missed TS surveillance regarding SG tube

. inspections.

50-454/455/94020-01

VIO

Failure to follow fire protection procedures..

>

]

50-454/455/95009-04

VIO

Failure to follow fire protection procedures,

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. _ . . . -

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. - - .

.

.

3

LIST OF ACRONYMS USED

ALARA

As Low As Reasonably Achievable

ASME

American Society of Mechanical Engineers

BOS

Byron Operating Procedure

BVS

Byron Surveillance Procedure

'

CC

Component Cooling Water System

CRDS

Control Rod Drive System

CV

Chemical and Volume Control System

DRPI

Digital Rod Position Indication

'

ECCS

Emergency Core Cooling Systems

4

E0P

Emergency Operating Procedure

ESF

Engineered Safety Feature

'

FW

Feedwater System

i

00S

Out of Service

RH

Residual Heat Removal System

RPC

Rotating Pancake Coil

SG

Steam Generator

SR

Source Range

SX

Essential Service Water

TS

Technical Specification

V&V

Verification and Validation

4

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15