IR 05000295/1985022

Insp Repts 50-295/85-22 & 50-304/85-23 on 850702-0805.No Violation or Deviation Noted.Major Areas Inspected:Licensee Action on Previous Insp Findings,Operational Safety & ESF Sys Walkdown & LERs

ML20137F954
Person / Time
Site:	Zion  File:ZionSolutions icon.png
Issue date:	08/23/1985
From:	Suermann J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20137F936	List: IR 05000295/1985022 ML20137F931
References
50-295-85-22, 50-304-85-23, NUDOCS 8508270134
Download: ML20137F954 (8)

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U.S. NUCLEAR REGULATORY COMMISSION

REGION III

Reports No. 50-295/85022(DRP); 50-304/85023(DRP)

Docket Nos. 50-295; 50-304 Licenses No. OPR-39; DPR-48 Licensee: Commonwealth Edison Company P. O. Box 767 Chicago, IL 60690 Facility Name: Zion Nuclear Power Station, Units 1 and 2 Inspection At: Zion, IL Inspection Conducted: July 2 through August 5, 1985 Inspectors: R. A. Hasse M. M. Holzmer L. E. Kanter J. N. Kish M. A. Ring

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Approved By: Jj. uermann, Acting Chief (LzuM 23,/?gs'

Reactor Projects 2A Date/

Inspection Summary Inspection on July 2 through August 5,1985 (Reports No. 50-295/85022(DRP);

50-304/85023(DRP))

Areas Inspected: Routine, unannounced resident and regional inspection of licensee action on previous inspection findings; operational safety and engineered safety features system walkdown; surveillance; maintenance; and licensee event reports. The inspection involved a total of 311 inspector-hours onsite including 35 inspector-hours onsite during off-shift Results: Of the five areas inspected, no violations or deviations were identifie PDR ADOCK 05000295 0 PDR

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DETAILS Persons Contacted K. Graesser, Station Manager

• G. Plim1, Superintendent, Production

• T. Rieck, Superintendent, Services

• E. Fuerst, Assistant Station Superintendent, Operations K. Kofron, Assistant Station Superintendent, Maintenance R. Budowle, Unit 1 Operating Engineer J. Gilmore, Unit 2 Operating Engineer L. Pruett, Rad Waste Operating Engineer

• W. Kurth, Assistant Superintendent

• M. Carnahan, Training Supervisor R Cascarano, Technical Staff Supervisor A. Ockert, Assistant Technical Staff Supervisor

• C. Schultz, Assistant Technical Staff Supervisor R. Aker, Station Health Physicist

• J. Ballard, Quality Control Supervisor D. Kaley, Quality Control Engineer W. Stone, Quality Assurance Supervisor D. McMenamin, Quality Assurance Engineer

• J. LaFontaine, Maintenance Staff Engineer

• Indicates persons present at exit intervie . Licensee Action on Previous Inspection Findings (Closed) Open Item (295/82020-01; 304/82018-02): Licensee to develop program to factor examination results into requalification progra Training Instruction (TI)-207. " Licensed Operator Retraining /Requali-fication Program", Revision 0, now requires the results of previous examinations to be factored into the training program. The inspector was satisfied that the program was in the process of implementation and had no further question (Closed) Open Item (295/82020-02; 304/82018-03): Training Instructions (TI) were not controlled. The TI's are now under the control of Zion Administrative Procedures (ZAP) ZAP 5-51-4, " Procedure Control and Approval", Revision 3, ZAP 5-51-5, " Procedure Content and Format",

Revision 4, and ZAP 2-52-1, " Training Program", Revision (0 pen) Open Item (295/82020-03; 304/82018-04): Lack of a training standard for maintenance training. A job analysis for maintenance training is in progress. An INPO accredited maintenance training program is expected to be implemented in late 198 _ - _ . .

(Closed) Open Item (295/82020-04; 304/82018-05): Licensee's QA training matrix is not implemented by procedure. The QA training matrix is now implemented by Nuclear Station's Department Directive (NSDD)-T03 and TI-508, "QA Training for Zion Station Personnel", Revision (0 pen) Open Item (295/82020-05; 304/82018-06): Annual retraining program for Radiation Chemistry Technicians (RCTs) was not defined. An INP0 accredited training program for RCTs is targeted for late 1986 which will include retraining requirements. The job analysis for this position was in progres (Closed) Open Item (295/82020-06; 304/82018-07): Licensee lacked a system for evaluating training programs. Training program evaluation is-now covered by TI-911, " Training Program Evaluation", TI-905, " Course Revision Process", and TI-912, " Training Program Development and Maintenance." An evaluation had recently been completed as part of the INP0 accreditation proces (Closed) Violation (295/82020-07B; 304/82018-08B): Failure to include introduction to QA in Nuclear-General Employee Training (NGET) lectur The lecture is now on videotape preventing repeat of this oversigh (Closed) Violation (295/82020-07C; 304/82018-08C): Failure to record out-of-tolerance diesel generator parameters. The inspector was satis-fied that this event represented an isolated case and did not reflect a programmatic problem. Also, a more formal review of the results of operation's department surveillances is now performed by the Operations Engineering Assistan (Closed) Violation (295/82020-07D; 304/82018-8D): Failure to record i valve stroke times. The inspector was satisfied that the event did not ,

represent a programmatic proble Also, in-service testing surveillances now receive a more formal review by technical staff personne (0 pen) Unresolved Item (295/82020-09;304/82018-10): Lack of a master

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schedule of required surveillances. The surveillance schedules continued i

to be departmentalized. Collectively they do represent a master schedule, although in different formats. The licensee is attempting to obtain the administrative support for a uniform master schedule. This item will remain open pending completion of this effor (Closed) Open Item (295/84025-03) Operation of Unit I with Loop A nominal Tavg 2 F below normal. Region III requested assistance from the Office of Nuclear Reactor Regulation (NRR) with respect to three aspects of this issue: Ensure " double-bookkeeping" of " generic margin" does not occu Evaluate " generic margin" with respect to 10CFR50.5 Confirmation of Westinghouse calculations and conclusion .

i j NRR provided the requested assistance and documented the effort in a Safety Evaluation Report (SER) issued June 27, 1985. The SER addressed each of the above issues and concluded that Commonwealth Edison's treat-ment of these issues was acceptable. NRR also points out that should the situation occur again a new and current analysis should be performed

for the new occurrence. The inspector has reviewed the Safety Evaluation Report and concurs with its conclusions. The licensee's efforts to identify and correct the cause of 2 temperature deviation have been successful to date. The licensee has therefore obtained an analysis from Westinghouse which concludes that the available Departure from Nucleate Boiling Ratio margins for the previous cycle (8) were unchanged by the reload and that operation in Cycle 9 with this condition is permissibl An onsite review of the Westinghouse analysis was conducted on June 12,

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1985. The inspector has no additional questions at this tim No violations or deviations were identifie . Summary of Operations Unit 1 Unit 1 operated at full power levels throughout the inspection perio Unit 2 Unit 2 operated at power levels as high as 93% at the beginning of the inspection period and is currently in coastdown in preparation for a refueling outag At 6:25 a.m. on July 18, 1985, the licensee declared the 28 diesel generator (DG) inoperable af ter it had tripped on an overspeed condition thereby placing the unit in a four hour action requirement to be in hot shutdown as required by Technical Specifications. An Unusual Event was declared at this tim Prior to t' 2B DG tripping, the 2B Residual Heat Removal (RHR) pump had been taken out of service for replacement of the lower motor bearin Technical Specification 4.8.3.C requires that when one of the two RHR pump systems is inoperable the remaining RHR system, both centrifugal charging pumps and safety injection pumps and associated standby AC and DC power supplies, be demonstrated to be operable immediately and daily thereafte Technical Specifications states further that if the conditions cannot be met, the reactor shall be brought to hot shutdown in four hours.

, At 7:46 AM, July 18,1985, the 2B DG was declared operab'le after suc-

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cessful completion of a surveillance test and the Unusual Event was terminate .

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. Operational Safety Verification and Engineered Safety Features System Walkdown The inspectors observed control room operations, reviewed 4pplicable logs and conducted discussions with control room operators from July 2 through August 5, 1985. During these discussions and observations, the inspec-tors ascertained that the operators were alert, fully cognizant of plant conditions, attentive to changes in those conditions, and took prompt action when appropriate. The inspectors verified the operability of selected emergency systems, reviewed tagout records and verified proper return to service of affected components. Tours of the auxiliary and turbine buildings were conducted to observe plant equipment conditions including potential fire hazards, fluid leaks, and excessive vibrations and to verify that maintenance requests had been initiated for equipment in need of maintenanc The inspectors, by observation and direct interview, verified that the physical security activities were being implemented in accordance with the station security pla The inspectors observed plant housekeeping / cleanliness conditions and verified implementation of radiation protection control From July 2 through August 5, 1985,'the inspectors walked down the accessible portions of the component cooling, auxiliary feedwater and service water systems to verify operability. The inspectors also witnessed portions of the radio-active waste system controls associated with radwaste shipments and barrelin These reviews and observations were conducted to verify that facility operations were in conformance with the requirements established under Technical Specifications, 10 CFR and administrative procedure No violations or deviations were identifie . Monthly Surveillance Observation The inspector observed Technical Specifications required surveillance testing on the service water, chemical and volume control system, and residual heat removal systems and verified that testing was performed in accordance with adequate procedures, the test instrumentation was cali-brated, that limiting conditions for operation were met, that removal and restoration of the affected components were accomplished, that test results conformed with Technical Specifications and procedure requirements and were reviewed by personnel other than the individual directing the test, and that any deficiencies identified during the testing were properly reviewed and resolved by appropriate management personne The inspector also witnessed portions of the following test activities:

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PT-2J Residual Heat Removal Pump Tests and Checks PT-9 Service Water Valves Operability Checks PT-20 Centrifugal Charging and Letdown System Power Operated Valve Tests No violations or deviations were identifie . Monthly Maintenance Observation Station maintenance activities on safety related systems and components listed below were observed or reviewed to ascertain whether they were conducted in accordance with approved procedures, regulatory guides, industry codes or standards, and in conformance with Technical Specification The following items were considered during this review: the limiting conditions for operation were met while components or systems were removed from service; approvals were obtained prior to initiating the work; activities were accomplished using approved procedures and were inspected as applicable; functional testing and/or calibrations were performed prior to returning ccmponents or systems to service; quality control records were maintained; activities were accomplished by quali-fied personnel; parts and materials used were properly certified; radiological controls wert implemented; and fire prevention controls were implemente Work requests were reviewed to determine status of outstanding jobs and

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to assure that priority is assigned to safety related equipment mainte-nance which may affect system performance.

, The following maintenance activities were observed or reviewed:

28 RHR Pump Bearing Replacement 1 MOV SI 8923A Limitorque Operator Environmental Qualification Inspection 2 M0V SI 8923A Limitorque Operator Environmental Qualification Inspection Following completion of maintenance on the RHR pump the inspector verified that these this system been returned to service properl No violations or deviations were identifie . Licensee Event Reports (LER) Followup Through direct observations, discussions with licensee personnel, and review of records, the following event reports were reviewed to determine

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that reportability requirements were fulfilled, immediate corrective action was accomplished, and corrective action to prevent recurrence had been accomplished in accordance with Technical Specifications. The LERs listed below are considered closed: *

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UNIT 1 LER N DESCRIPTION 82-24-01 SI Accumulator Tank Level Transmitters out of Tolerance 84-40 Missed Quarterly Surveillance of IRIA-PR40 85-13-01 Inadvertent Dilution of RWST and Reactor Cavity 85-18 Containment Isolation Valve Leakage Exceeding Limits 85-19 Inadvertent ESF Actuation 85-20 Failure to Continuously Record Monitors During Containment Purge 85-21 Inadvertent Trip of Reactor Trip Breakers While in Cold Shutdown 85-23 Failure to Review Temporary Procedure Change Within 14 Days 85-24 Reactor Trip From Low Steam Generator Level 85-25 Manual Reactor Trip UNIT 2 LER N DESCRIPTION 84-33 Missed Quarterly Surveillance of 2RIA-PR40 85-01-01 28 Diesel Generator Trip Regarding LER 295/85-19, the licensee will submit a revised LER to elaborate on the root cause of the trip and corrective action involve This matter is designated an Open Item pending review of the revised LER and the licensee's corrective actions (295/85022-01).

During inspection of the missed quarterly surveillance of Unit 1 and 2 containment atmosphere monitors (SPINGS), problems with implementation of the modification which installed the SPINGS were -identified. These and other problems had already been documented on two discrepancy records (DR). Correction of these items will be tracked as an Open Item .

(295/85022-02;304/85023-01).

No violations or deviations were identified.

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. .. Open Items Open Items are matters which have been discussed with the licensee which will be reviewed further by the inspector and which involve some action on the part of the NRC or licensee or both. Two open items disclosed during this inspection are discussed in paragraph . Exit Interview The inspectors met with licensee representatives (denoted in Paragraph 1)

throughout the inspection period and at the conclusion of the inspection on August 5, 1985 to summarize the scope and findings of the inspection activities. The licensee acknowledged the inspectors' comments. The inspector also discussed the likely informational content of the inspec-tion report with regard to documents or processes reviewed by the inspector during the inspection. The licensee did not identify any such documents or processes as proprietar At the exit interview, the inspectors noted that station housekeeping had improved in the auxiliary building and crib house. The inspectors also noted that the station's intention to implement the company's Total Job Management system appeared to constitute a considerable improvement in both job planning and material histor i

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