IR 05000302/1989008

Insp Rept 50-302/89-08 on 890401-28.Violations Noted.Major Areas Inspected:Plant Operations,Security,Radiological Controls,Nonconforming Operations Repts,Facility Mods & Followup of Onsite Events

ML20246J516
Person / Time
Site:	Crystal River
Issue date:	05/10/1989
From:	Crlenjak R, Holmesray P, Tedrow J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
To:
Shared Package
ML20246J508	List: IR 05000302/1989008 ML20246J501 ML20246J511
References
50-302-89-08, 50-302-89-8, NUDOCS 8905170101
Download: ML20246J516 (12)

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• UNITED STATES

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• NUCLEAR REGULATORY COMMISSION

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n R EGION 11 101 MARIETTA STRE ET, j l 3 j

! * t ATLANTA, GEORGIA 30323 j k % ,s

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i Report No: 50-302/89-08 Licensee: Florida Power Corporation ^

3201 34th Street, South '

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St., Petersburg, FL 33733

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Docket No: 50-302 License No.:'DPR-72: ,

Facility Name: Crystal River 3 Inspection Conducted: April 1 - April 28, 1989 Inspectors: Yfl$ . x pwo ./ 0( 6/-/o/39 P.Holme's-Ray,Sen[6rResidentInspector .

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4//o/39 J..Tedrov, sidentIns@ctor Date Signed Approved by: /,

R. (rlenjak, SeftTon Chief r e #!6 Dite /Sigtfed Division of Reactor Projects j SUMMARY Scope: This routine inspection was conducted by two resident inspectors in the areas of plant operations, security, radiological controls, nonconforming operations reports, facility modifications, followup of onsite events, and licensee action on previous inspection item Numerous facility tours were conducted and facility operations observe Some of these tours and observations were conducted on backshift Results: One violation was identified: Failure to take adequate corrective action to establish correct radiation monitor trip setpoints (paragraph 3.c).

A weakness was noted in the licensee's review of procedure changes (paragraph 2.b.(9)(a)).

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I REPORT DETAILS l Persons Contacted Licensee Employees

• K. Baker, Manager, Nuclear Engineering Assurance

• Bolt, Vice President, Nuclear Production B. Hickle, Manager, Nuclear Plant Operations

• K. Lankaster, Manager, Site Nuclear Quality Assurance

• P. McKee, Director, Nuclear Plant Operations

• V. Roppel, Manager, Nuclear Operations Maintenance and Outages

• Rossfeld, Manager, Nuclear Compliance

• D. A. Shook, Manager, Nuclear Electrical /I&C Engineering

• P.R. Tanguay, Manager, Nuclear Operations Engineering

• L. Ticione, Manager, Nuclear Procurement Engineering Services

• C, Tillman, Manager, Material Control J. Tunstill, Senior Nuclear Licensing Engineer E. Welch, Manager, Nuclear Electrical / Instrumentation and Control Engineering Services

• K. Wilson, Manager, Nuclear Licensing Other licensee employees contacted included office, operations, engineering, maintenance, chemistry / radiation and corporate personne * Attended exit interview Acronyms and initialisms used throughout this report are listed in the last paragrap . Review of Plant Operations (71707)

The plant remained in the cold shutdown (Mode 5) condition. for .the duration of this inspection period, Shif t Logs and Facility Records (71707)

The inspector reviewed records and discussed various entries with

, operations personnel to verify compliance with the Technical Specifications (TS) aad the licensee's administrative procedure The following records were reviewed:

Shift Supervisor's Log; Reactor Operator's Log; Outage Shift Manager's Log; Shift Relief Checklist; Auxiliary Building Operator's Log; Active Clearance Log; Daily Operating Surveillance Log; Short Term Instructions (STI); and Selected Chemistry / Radiation Protection Log In addition to these record reviews, the inspector independently verified clearance order tagout _ _ _ _ _ - _ _ _ _ - _ _ _ _ _ _ _ -

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No violations or deviations were identifie i Facility Tours and Observations (71707)

Throughout the inspection period, facility tours were conducted to observe operations and maintenance activities in progres Some operations and maintenance activity observations were conducted during backshifts. Also, during this inspection period, licensee meetings were attended by the inspector to observe planning and management activitie The facility tours and observations encompassed the following areas:

security perimeter fence; control room; emergency diesel generator room; auxiliary building; reactor building; intermediate building; battery rooms; and, electrical switchgear room During these tours, the following observations were made:

(1) Monitoring Instrumentation - The following instrumentation and/or indications were observed to verify that indicated parameters were in accordance with the TS for the current operational mode:

Equipment operating status; area atmospheric and liquid radiation monitors; electrical system lineup; reactor operating parameters; and auxiliary equipment operating parameter No violations or deviations were identifie (2) Safety Systems Walkdown (71710) - The inspector conducted a walkdown of the Decay Heat and Nuclear Services Seawater sytems to verify that the lineups were in accordance with license requirements for system operability and that the system drawings and procedures correctly reflected "as-built" plant condition No viciations or deviations were identifie , (3) Shif t Staffing (71707) - The inspectors verified that operating shift staffing was in accordance with TS requirements an.d that control room operations were being conducted in an orderly and professional manner. In addition, the inspectors observed shift turnovers on various occasions to verify the continuity of plant status, operational problems, and other pertinent plant information during these turnover No violations or deviations were identifie (4) Plant Housekeeping Conditions (71707) - Storage of material and components, and cleanliness conditions of various areas throughout the facility were observed to determine whether safety and/or fire hazards existe .

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Even taking into account that the plant is in a major . outage, housekeeping during this reporting period has been less than adequat Barrels of removed anti-contamination clothing were seen to be overflowing on two consective days. Areas where work had taken place were left with trash and unused material lying abou In general,. housekeeping has been degrade No violations or deviations were identifie (5) Radiological Protection Program (71707) - Radiation protection control activities were observed to verify that these activities were in conformance with the facility policies and procedures, and in compliance with regulatory requirement These observations included:

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Entry to and exit from contaminated areas, including step-off pad conditions and disposal of contaminated clothin Area' postings and control Work activity within radiation, high radiation, and contaminated area Radiation Control Area (RCA) exiting practice Proper wearing .of personnel monitoring equipment, protective clothing, and respiratory equipmen Area postings were independently verified for accuracy by the inspector. The inspector also reviewed selected Radiation Work Permits (RWPs) to verify that the RWP was current and that the controls were adequate.

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i No violations or deviations were identifie (6) Security Control (71707) - In the course of the monthly

, activities, the inspector included a review of the licensee's physical security program. The performance of various shifts of the security force was observed in the conduct of daily

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activities to include: protected and vital area access controls; searching of personnel, packages, and vehicles; badge issuance and retrieval; escorting of visitors; patrols; and compensatory post In addition, the inspector observed the operational status of Closed Circuit Television (CCTV) monitors, the Intrusion Detection system in the central and secondary alarm j stations, protected area lighting, protected and vital ' area l barrier integrity, and the security organization interface with  ;

operations and maintenanc No violations or deviations were identifie .

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e (7) Fire Protection (71707) - Fire protection activities, staffing and equipment were observed to verify that fire brigade staffing was appropriate and that fire alarms, extinguishing equipment, actuating controls, fire fighting equipment, emergency equipment, and fire barriers were operabl On April 20, 1989 the licensee conducted a fire drill in the auxiliary buildin The drill was a fire starting in stored contaminated trash then spreading to cable tray The response and action of the fire team was excellent,

, No violations or deviations were identifie (8) Surveillance (61726) -

Surveillance tests were observed to verify that approved procedures were being used; qualified personnel were conducting the tests; tests were adequate te verify equipment operability; calibrated equipment was utilized; and TS requirements were followe The following tests were observed and/or data reviewed:

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SP-184A, Sodium Hydoxide Flow Verification: "A" Trai SP-901, 4160 kv ES Bus "B" Undervoltage Trip Test and Auxiliary Relay Calibratio PT-321, Decay Heat Pump 3B Minimum Flow Tes No violations or deviations were identifie (9) Maintenance Activities (62703) -

The inspector observed maintenance activities to verify that correct equipment clearances were in effect; work requests and fire prevention work permits, as required, were -issued and being followed; quality control personnel were available for inspection activities as required; and, TS requirements were being followe f Maintenance was observed and work packages were reviewed for the following maintenance activities:

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Snubber testing in accordance with procedure PT-130, Hydraulic Pipe Snubber Test Procedure. The inspector noted that the personnel performing the procedure were well trained and performed the procedure in an efficient and accurate manne Snubber maintenance in accordance with procedure MP-174, Power Piping Snubber Rebuilding Procedure. This procedure i was reviewed for the snubber tested by PT-130 mentioned abov .

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Refurbishment and testing of.a reactor coolant pump seal package in accordance with procedure MP-16 Inspection and Repair of the "B" Nuclear Services Seawater Pump (RWP-28) in accordance with procedures MP-150, Maintenance of Raw Water Pumps, and MP-122, Disassembly and Reassembly of Flanged Connection Replacement of Cell #59 for the "A" station battery in accordance with procedure MP-401, DC System Maintenanc Troubleshooting of Reactor Coolant System (RCS) . flow transmitter RC-14B-DPT3 in accordance with procedures MP-531, Troubleshooting Plant Equipment, SP-112,:

Calibration of the Reactor Protection System, andlSP-115, Reactor Protection System Response Time Tes Cleaning of the "B" Nuclear Services Heat Exchanger (SWHE-1B) in accordance with procedure PM-112, DC, SW and SC Heat Exchanger Maintenance Inspection / Cleaning / Shooting and Pluggin Tensioning of the motor stand .for the "A" Reactor Coolant Pump (RCP-1A) in accordance with procedure MP-115A, Reactor Coolant Pump Inspection and Replacemen Inspection of valves CAV-3 and CAV-5 for environmental qualification in accordance with approved work instructions and procedure MP-402A, Maintenance' of Limitorque Valve Operator Type SMB-00 (a) During a review of procedure MP-166, RC Pump Seal Package Refurbishment and Testing, it was noted that an interim change had been issued to correct referenced enclosure and step numbers. A weakness of less than adequate review of procedure changes is indicated by the need to make additional changes to correct step and enclosure number ,

(b) During the performance of procedure PM-112, the, inspector noted that certain steps of the procedure had not been performed by the craf Section 4.3 of the procedure specifies the steps to be performed for cleaning the heat exchanger and directs that steps 4.1.1 through 4.1.5 be performed. These steps contained requirements for removal and reinstallation of the access doo Specifically the inspector noted that step 4.1.3, which was a Quality Control Hold Point to inspect new bolting and gasket material, and step 4.1.5, which required the access door

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bolts be torqued, had not yet been complete This L observation was discussed with maintenenace personnel- who L stated that these steps were not applicable until the heat exchanger cleaning was completed in section 4.3. Althoug these steps were not applicable, the inspector considered the steps of procedure PM-112 to' be confusing. Licensee

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personnel agreed with the inspectors comment and plan to-clarify the procedur This same procedure was recently revised to satisfy NRC concerns' expressed in NRC Inspection Report 50-302/88-2 Apparently the licensee's ef forts .to improve procedure PM-112 were unsuccessfu l Inspector Followup Item (302/89-08-01): Review the clarifications to procedure PM-11 (10) Radioactive Waste. Controls (71707) - Selected liquid releases

.and solid waste compacting were observed to verify that approved procedures were utilized, that appropriate. release approvals were obtained, and that required surveys were take No violations or deviations were identifie . Review of Nonconforming Operations Reports (71707)

The inspectors reviewed Nonconforming Operations Reports (NCORs) to verify the following: TS are complied with, corrective actions as identified in the' reports or during subsequent reviews have been accomplished or are being pursued for completion, generic items are identified and reported as required by 10 CFR Part 21, and items are reported as required by T All NCORs were reviewed in accordance with the current NRC Enforcement Polic NCOR 89-62 reported that a visual inspection of the "A" Reactor Coolant Pump (RCP-1A) motor found deficiencies. The licensee's

, inspection of the motor revealed that the rotor cage had shifted and was resting against the rotor fan. In addition, during the removal l

and inspection of the rotor a few drive end space blocks were found

! loose and had tilted slightly. An inspection of RCP-1B and RCP-1C motors revealed similar deficiencies. An inspection of RCP-10 motor showeo only that the rotor cage had shifted and was resting against i the rotor fa An analysis of these problems was performed by the vendor (General Electric Canada Inc.). The shift of the rotor was considered to be a minor problem which could result in contact between the motor's rotor cage shorting ring and the rotor f an which could result in arching during a motor star The vendor recommended this condition be repaired when convenien The loose space blocks are considered to

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be a more serious problem and could result in stator damage and a motor trip if the space blocks become dislodge The vendor recommended this condition be repaired prior to starting the pump The licensee has subsequently repaired the motors for RCP-1A, RCP-1B and RCP-1C and plans to repair RCP-10 during the next refueling outage presently scheduled for Mxrch 199 Inspector Followup Item (302/89-08-02): . Review the licensee's activities to repair the motor for RCP-I b. NCOR 89-65 reported that during an inspection and repair of the "B" Nuclear Services Seawater Pump (RWP-28) excessive corrosion was noted on.the pump's tube tension adaptor. The failure of this part could cause excessive pump vibration and subsequent pump failure. This pump has been in service for approximately 15 years. The licensee-has subsequently replaced the defective parts and has discussed this problem with the pump's manufacturer (Bingham Willamette) who recommended that the other seawater pumps be inspected for similar damage. The licensee plans to inspect the other pumps (RWP-3A and RWP-38) during the next refueling outage. The pump manufacturer concurred that.the pumps could be operated without problems for this interva Inspector Followup Item (302/89-08-03): Follow the licensee's activities to inspect and repair RWP-3A/3B for corrosion damag c. NCOR 89-77 reported that the trip setpoint associated with radiation monitor RMA-2, Auxiliary Building (AB) and Fuel Handling Area Exhaust Duct Ponitor, was found above the limit required by TS 3.3.3.9. This condition was identified by the licensee on April 13, 1989 during the generation of a routine weekly AB release permit. The monitor's trip setpoint was found to be off scale high (greater than 1,000,000 counts per minute (CPM)) whereas the required setpoint was approximately 5,200 CPM. The licensee's preliminary investigation revealed that this condition had probably existed since approximately April 8 when the monitor was calibrated. The higher trip setpoint

, would not have alerted operators to a potential release in excess of the radiation limits allowed at the site boundar The licensee has experienced previous problems with establit,hing correct radiation monitor trip setpoint On March 25, 1988 the licensee reported (LER 88-10) that the trip setpoint for radiation monitor RMA-2 was set too high. The licensee attributed the cause for this event to be a deficient procedure and implemented corrective action to revise the procedure. This event was discussed in NRC Inspection Report 50-302/88-14 and was considered by the NRC to be.'a Licensee Identified Violation (LIV 88-05). In September, 1988 o effluent monitor setpoints for a liquid release were round to be set l improperly. The licensee attributed the causes for this event to be personnel error and a lack of procedural guidance. The licensee's

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corrective action for- this event included revising the specific procedure to provide more guidance. This event was discussed in NRC l Inspection Report 50-302/88-29 and was considered to be a LIV (LIV 88-10).

Althot.gh the licenset nas taken corrective action for each of the specific events discussed above, this corrective action was insufficient to encompass the general overall. problem of deficien procedures for establishing correct radiation monitor trip setpoints and resulted in another recurrence of the nonconformance on April 1 Failure to take sufficient corrective action to prevent recurrence of a nonconformance is contrary to the requirements of 10 CFR Part 50 Appendix B, Criterion XVI and is considered to be a violatio Violation (302/89-08-04); Failure to take adequate corrective action to establish correct radiation monitor trip setpoint . Installation and Testing of Modifications (37828)

Installation of new or modified systems were reviewed te verify that the changes were reviewed and approved in accordance with 10 CFR 50.59, that the changes were performed in accordance with technically adequate and approved procedures, that subsequent testing and test results met acceptance criteria or deviations were resolved in an acceptable manner, and that appropriate drawings and facility procedures were revised as necessary. This review included selected observations of modifications and/or testing in progres During a review of modification package MAR 87-01-19-01, Reactor Building Depressurization, the inspector noticed that an attachment to the modification safety evaluation included proposed revisions needed to the Technical Specifications and the Final Safety Analysis Report (FSAR).

This modification changed the engineered safeguards Reactor Building (RB)

isolation close signals from the RB purge 48 inch butterfly valves (AHV-1A/1B/1C/1D) to 6 inch hydrogen vent valves (LRV-70/71/72/73). The smaller vent line is to be used to allow RB depressurizction during operating modes 1 through 4 when the RB purge valves are locked in the

, closed position. Upon reviewing the proposed FSAR change, the inspector noted that the description of the RB depressurization system was not included. A review of FSAR Section 5.5, Reactor Building Venti 11ation a% Purge Systems, revealed that the hydrogen vent system was also not deu ribed.. Further, the inspector noted that the RB vent 111ation and ext.au>t flowrates assumed while the reactor is operating in paragraph 5.5.1.2.d would be deminished by the use of the smaller depressurization system, yet no proposed change for this paragraph was include These matters were discussed with licensee personnel. Although the proposed FSAR. revision had not yet been reviewed and approved for submittal to the NRC, licensee personnel agreed that clarifications needed to be made to the FSAR to adequately describe the RB ventilation syste . _ _ _ _ _ - _ _ _ _ _ _ _ - _ - _ _ _ _ _ _ - _ _ -

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l Inspector Followup Item (302/89-08-05): Review the licensee's revision to the FSAR regarding the RB ventilation syste . ' Followup of~Onsite Events (93702)

On April 9 at approximately 11:49 an inadvertent startup of the Emergency Diesel Generators (EDG-1A/18) occurre The plant was in the cold shutdown condition (Mode 5) with offsite power being supplied from the fossil units 4160 volt startup bu The nuclear Unit #3 has the capability of receiving offsite power from the normal Unit #3 startup transformer or from the fossil unit 4160 volt startup bu Due to maintenance being performed on the Unit #3 startup transformer, the alternate 4160 volt startup bus was supplying offsite. power. At .11:49 p.m. fossil unit personnel started a boiler feedwater pump which caused a voltage drop on the 4160 volt busses. The Unit #3 undervoltage relays detected the degraded bus condition and started the EDGs as designed. The undervoltage condition cleared before the diesels were automatically

. loaded onto the site emergency busse _ Licensee Action on Previously Identified Inspection Findings (92702 &

92701) (Closed) Violation 302/88-29-02: Failure to have two battery chargers to supply the "B" Station Batter The inspector reviewed and verified implementation of the corrective actions stated in the FPC response letter dated December 16, 198 (Closed) IFI 302/87-10-05: Review the actions for a disconnected wire from the control switch for valve MUV-2 This item was previously discussed in NRC Inspection Report 50-302/88-1 The licensee has revised procedure CP-113B, Work Request Evaluation, Planning, and Scheduling (revision 2 dated March 1,1989) to implement procedure SP-850, Main Control Board Wiring and Housekeeping Inspection, whenever work is performed behind the

< applicable sections of the main control boar ' (Closed) IF1 302/88-26-02: Follow the licensee's activities to inspect safety related pumps for loose impeller nut This item was previously discussed in NRC Inspection Report 50-302/88-31. The licensee has completed the inspection of pumps SWP-1A/1B and DCP-1A/1B and has secured the impeller nuts. Most pump impeller nuts were replaced with new nuts which contained a self locking inser The impeller nut for the south pump of SWP-1A was secured using ~ locktite. The licensee has revised applicable maintenance procedures to require the impeller nuts be secured using locktite or similar thread securing compound .

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10 Exit Interview (30703)

The inspectors met with licensee representatives (denoted in paragraph 1)

at the conclusion of the inspection on April 28, 198 During tnis meeting, the inspectors summarized the scope and findings of the inspection as they are detailed in this report with particular emphasis on the

)' violation and Inspector Followup Items (IFI).

l The licensee representatives acknowledged the inspector's comments and did

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not identify as proprietary any of the materials provided to or reviewed

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by the inspectors during this inspectio Item Number Description and Reference 50-302/89-08-01 IFI - Review clarifications to procedure PM-11 /89-08-02 IFI - Review the licensee's activities to repair the motor for RCP-1 /89-08-03 IFI - Follow the licensee's activities to inspect and repair pumps RWP-3A/3B for corrosion damag l 50-302/89-08-04 Violation - Failure to take adequate corrective action to establish correct radiation monitor trip setpoint /89-08-05 IFI - Review the licensee's revision to the FSAR regarding the RB ventilation syste . Acronyms and Abbreviations AFW - Auxiliary Feedwater System CCTV - Closed Circuit Television CFR - Code of Federal Regulations DEV - Deviation

. ECCS - Emergency Core Cooling System (s)

EDG - Emergency Diesel Generators ,

FSAR - Final Safety Analysis Report I&C - Instrumentation and Control IFI - Inspector Followup Item ISI - Inservice Inspection IST - Inservice Test LER - Licensee Event Report MAR - Modification Approval Record NCOR - Nonconforming Operation Report NRC - Nuclear Regulatory Commission PM - Preventive Maintenance QC - Quality Control

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QA - Quality Assurance RCA - Radiation Control Area RCS - Reactor Coolant System RO - Reactor Operator RWP - Radiation Work Permit S/G - Steam Generator SP - Surveillance Procedure STI - Short Term Instruction TS - Technical Specification UNR - Unresolved Item VIO - Violation i

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