ML20127L975

Insp Repts 50-313/85-13 & 50-368/85-13 on 850501-31. Violations Noted:Fire Doors Left Open & Inadequate Emergency & Abnormal Procedure Reviews by Licensed Operators

ML20127L975
Person / Time
Site:	Arkansas Nuclear
Issue date:	06/26/1985
From:	Harrell P, Johnson W, Martin L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20127L947	List: IR 05000313/1985013 ML20127L942 ML20127L961
References
50-313-85-13, 50-368-85-13, IEB-84-02, IEB-84-03, IEB-84-2, IEB-84-3, NUDOCS 8507010026
Download: ML20127L975 (13)

See also: IR 05000368/1985013

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APPENDIX B

U. S. NUCLEAR REGULATORY COMMISSION

REGION IV

NRC Inspection Report: 50-313/85-13 Licenses: DPR-51

50-368/85-13 NPF-6

Dockets: 50-313

50-368

Licensee: Arkansas Power and Light Company (AP&L)

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P. O. Box 551

Little Rock, Arkansas 72203

Facility Name: Arkansas Nuclear One (ANO), Units 1 and 2

Inspection At: ANO Site, Russellville, Arkansas

Inspection Conducted: May 1-31, 1985

Inspectors: M 8 ddIv//S

W."D.~Johnsopf Senior Resident D6te/

Reactor Inspector

(pars. 1, 3, 4, 5, 6, 7, 8)

h/ l A

P."H' Harrb y Resident Reactor Baty~

Inspector

(pars. 1, 2, 5, 6, 7, 8, 9)

Accompanying Personnel:

G. S. Vissing, Project tianager, Operating

Reactor Branch 4

Approved: /3

~ LI E. Martin'vChief, Reactor

4

Bate /

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Project Section 2A

Inspection Summary

Inspection Conducted May 1-31, 1985 (Report 50-313/85-13)

Areas Inspected: Routine, unannounced inspection including operational safety

verification, maintenance observations, surveillance, operator requalification

training, maintenance records review, followup on previously identified items,

and followup on IE Bulletins.

The inspection involved 76 inspector-hours (including 7 backshift hours) onsite

by two NRC inspectors.

8507010026 050626

DR ADOCK 0500

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Results: Within the seven areas inspected, no violations were identified.

Inspection Summary

Inspection Conducted May 1-31, 1985 (Report 50-368/85-13)

l Areas Inspected: Routine, unannounced inspection including operational safety

verification, maintenance observations, surveillance, operator requalification

training, maintenance records review, followup on previously identified items,

followup on IE Bulletins, and followup on licensee event reports.

The inspection involved 95 inspector-hours (including 9 backshift hours) onsite

by two NRC inspectors.

Results: Within the_efght areas inspected, two violations were identified

(fire doors left open, paragraph 5, and inadequate emergency and abnormal

j procedure reviews by licensed operators, paragraph 9).

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DETAILS

l '1. Persons Contacted

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• J. Levine, ANO General Manager

! *B. Baker, Operations Manager

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D. Bennett, Mechanical Engineer

M. Bolanis, Health Physics Superintendent

M. Browning, Maintenance Engineer

• P. Campbell _, Licensing Engineer

• T. Cogburn, Special Projects Manager

J. Constantin, Unit 2 Operations Trainer

M. Coombs, Civil Engineer

l *L. Dugger, Acting I&C Maintenance Superintendent i

E. Ewing, Engineering & Technical Support Manager

E. Force, Unit 1 0- ations Training Supervisor

L. Gulick, Unit . arations Superintendent

D. Hamblen, Quality Control Engineer i

R. Hargrove, Unit 2 Classroom Lead Trainer 1

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G. Helmick, Planning & Scheduling Supervisor

H. Hollis, Security Coordinator

• L. Humphrey, Administrative Manager

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P. Kearney, Mechanical Engineer

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J. Lamb, Safety and Fire Protection Coordinator *D. Lomax, Licensing

Supervisor

B. McCord,-Planning and Scheduling Coordinator

! J. McWilliams, Unit 1 Operations Superintendent

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J. Montgomery, Human Resources Supervisor *M. Pendergrass, Acting

Engineering & Technical Support Manager

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V. Pettus, Mechanical Maintenance Superintendent *D. Provencher, Quality

l Engineering Supervisor

l R. Rispoli, Fire Protection Specialist

P. Rogers, Plant Licensing Engineer

D. Russell, Electrical Engineer

l L. Sanders, Maintenance Manager

l *L. Schempp, Nuclear Quality Control Manager *C. Shively, Plant

Engineering Superintendent

• R. Simmons, Planning and Scheduling Supervisor *G. Storey, Safety and

Fire Protection Coordinator

l L. Taylor. Operations Technical Engineer

R. Tucker, Electrical Maintenance Superintendent

i R. Turner, Electrical Engineering Supervisor *J. Vandergrift, Training

Superintendent

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D. Wagner, llealth Physics Supervisor

l B. West, Instrumentation and Controls Supervisor

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D. Whiting, Mechanical Maintenance Supervisor

I G. Wrightam, Instrumentation and Controls Supervisor

i C. Zimmerman, Operations Technical Support

j *Present at exit interview.

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.. ' The.; inspectors also coritact'ed 'other plant personne,1,fnclhding operators, #

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techn , .~,icians,

and_ administrative

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2.* . Foll'owup'on Previou3 ,y Identified Items (Units 1 and 2)

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7, 4 (C]osed) Open It,ue313'/8504-02; 368/8504-03: Revision of the 1985\

f f quality assurpnce.(QA) audit schedule. ,

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L t 6-/ - klicenseehasrevisedthe1985-QAauditscheduletoinclude

~ ~ previously omitted. audits required by Technical Specification

l6.5.2.8.' The audit sl:hedule now appears to be complete and

meets-the Technical Specification audit requirements.

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(C40 sed)' Cpen Item 313/8504-04; 368/8504-05: Revision of audit

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The:ltcensee has revised the QAP-9 audit checklist to require

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.w 'thst alreview be performed to specifically address the use of

'sipervisofsasdesignverifiers. In addition, the licensee has

( required t. hat futste audit reports written in this area include

a specific-discussion of the audit results of the use of

- ,stpervisdis 'as design ' verifiers.

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(CTosed) ~ Open Item 31378504-05; 368/8504-06:

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Form used for the audit

schedule.

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%U v. Tiie licensee reviewed the audit scheoule format form specified

J%yjf , e_O by, the proce'duYe and the form currently in use by the QA organ-

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fiation. 3Thotreview concluded that the more detailed form used

by the QA-organization would be required for the preparation of

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., future audit schedules.

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<4 + ~~(Closed) Open Item 313/0504-06; 368/8504-07: Inclusion of checklist

. .g y rmtision' numbers in audit reports.

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y The licensee now requires that the revision number of the

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5 fchecklist used to perform an audit be included in the audit

, Y ' report. Ose of the revision number will ensure adequate

/, j,1 . trackability for record purposes.

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3. ' Licence'e' Event Report (LER) Followup (Unit 2)

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'"Thrdujhdirectt obst.rvation, discussions with licensee personnel, and

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. + . review'ol~reco'rds, the following Unit 2 event reports were reviewed to

#n' determine.that reportability requirements were fulfilled, immediate

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J corfectivu action was accomplished,'and corrective action to prevent

P (* - recurrihce has been accomplished in accordance with Technical

!' Speciftcatlons,

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%., d , 81-017/01T-1 , 83-025/01T-0

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84-009-00

84-025-00

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These LERs reported calibration or time response degradation problems with

reactor coolant system resistance temperature detectors (RTDs). The cause

of the time response degradation was determined to be the degradation of

the couplant used to mate the RTD and the thermowell. The licensee has

replaced the RTDs with a model made by the Weed Instrument Company. This

model is designed such that no couplant should normally be required.

Prior to replacement of- the RTDs, the thermowells were thoroughly cleaned.

The licensee is continuing to-monitor the time response of the RTDs

monthly.

No violations or deviations were identified.

4. Followup on IE Bulletins (Units 1 and 2)

A. IE Bulletin 84-03

This bulletin, entitled " Refueling Cavity Water Seal," was issued on

August 24, 1984. The licensee provided written responses to the

bulletin, as required, in letters dated October 16, 1984, and

November 26, 1984, for Units 1 and 2, respectively. Tnese responses

covered the following key points:

. The ANO units do not use a pneumatic seal as a portion of the

reactor cavity water seal and thus are not subject to a failure

similar to the one described in the bulletin.

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The ANO seal plates are annular plates made of stainless steel,

held in place with bolts or studs, and sealed with rubber

gaskets.

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Potential for leakage past the gaskets exists and leakage has

been observed, but it was estimated at less than 10 gallons per

minute.

. There are procedures in place for handling any such leakage.

. Analysis indicated that plate gross failure could not be caused

by dropping a fuel assembly on the seal plate.

. If the water in the spent fuel pool were drained to the level of

the reactor vessel flange, the active height of fuel in the

spent fuel pool would remain covered.

The NRC inspector reviewed the above responses, reviewed

associated procedures and drawings, and observed seal plate

operations during the recent refueling outages for Units 1 and

2. The emergency procedures for transfer canal seal plate

gasket failure are provided as attachments to the refueling

shuffle procedures.

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No violations or deviations were identified. The NRC inspector's

review of this bulletin is complete.

B. IE Bulletin 84-02

This bulletin, entitled " Failures of General Electric Type HFA Relays

in use in Class 1E Safety Systems," was issued on

March 12, 1984. The licensee provided written responses to this

bulletin in letters dated July 20, 1984, and February 11, 1985.

The licensee found that they had 102 relays of the type described in

the bulletin installed in safety-related systems. The licensee

implemented a program for inspection of these relays and also those

'in nonsafety-related systems. Some of the inspections were witnessed

by the NRC inspector. During the recent refueling outages, the

licensee replaced the HFA relays in safety-related systems with new

h General Electric Century series relays. The NRC inspector reviewed

the completed job orders for this replacement.

l The licensee's response informed the NRC of a similar problem

experienced with Potter & Brumfield (P&B) model MDR 137-8 and

MDR 138-8 relays in Unit 2. The P&B relays were replaced by new P&B

relays of like kind in both the third and fourth refueling outages.

During the fifth refueling outage, the licensee plans to replace the

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P&B relays with an improved model which is being developed and tested

by P&B.

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No violations or deviations were identified. The NRC inspector's

review of this bulletin is complete for Unit 1, but this bulletin

remains open for Unit 2 pending replacement of the P&B relays.

5. Operational Safety Verification (Units 1 and 2)

The NRC inspectors observed control room operations, reviewed applicable

logs, and conducted discussions with control room operators. The

l inspectors verified the operability of selected emergency systems,

j reviewed tagout records, verified proper return to service of affected

components, and ensured that maintenance requests had been initiated for

equipment in need of maintenance. The inspectors, by observation and

direct interview, verified that the physical security plan was being

implemented in accordance with the station security plan. The inspectors

l Verified implementation of radiation protection controls during plant

i activities.

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l The NRC inspectors toured accessible areas of the units to observe plant

equipment conditions, including potential fire hazards, fluid leaks, and

excessive vibration. The inspectors also observed plant housekeeping and

cleanliness conditions during the tour. It was noted to licensee

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h personnel that the 404 elevation in Unit 2 needed additional housekeeping

l' attention. The licensee cleaned up the identified area immediately. The

p NRC inspectors also informed licensee personnel that the Unit 2 upper

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north piping penetration room needed additional housekeeping attention.

. During a tour of the Unit 2 auxiliary building on May 18, 1985, the NRC

inspector found two fire doors ajar on two occasions each. These doors

lead from the main auxiliary building stairway to elevations 335 and 354

and are numbered 213 and 235, respectively. The NRC inspector shut the

doors each time they were found ajar. The doors had to be shut by hand

l since the automatic door closers were not powerful enough to overcome the

l air flow through the doors. The licensee's failure to maintain these

l doors shut is a violation of Technical Specification 3.7.11.

(368/8513-01)

The NRC inspectors walked down the accessible portions of the Unit 2

containment spray system. The walkdown was performed using Procedure

l 2104.05 and Drawing M-2236. During the walkdown, the NRC

inspectors noted that two valve numbers provided on the valve lineup did

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not agree with the valve numbers shown on the drawing or the tags

installed on the valves. Licensee personnel stated the discrepancies

would be corrected.

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 procedures.

6. Monthly Surveillance Observation (Units 1 and 2)

l- The NRC inspectors observed the Technical Specification required

surveillance testing on the Unit 1 station battery (Procedure 1307.16)

and verified that testing was performed in accordance with

adequate procedures, test instrumentation was calibrated, limiting

- conditions for operation were met, removal and restoration of the affected

components were accomplished, test results conformed with Technical

Specification and procedure requirements, test results were reviewed by

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personnel other than the individual directing the test, and any

deficiencies identified during the testing were properly reviewed and

resolved by appropriate management personnel.

The inspectors also witnessed portions of the following test activities:

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Unit 2 diesel generator 18-month operational test (Procedure 2103.26,

Supplement 4)

i . Unit 2 charging pump monthly test (Procedure 2104.02)

. Unit 2 service water pump monthly test (Procedure 2104.29)

No violations or deviations were identified.

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7. Monthly Maintenance Observation (Units 1 and 2)

Station maintenance activities of safety-related systems and components

listed below were observed to ascertain that they were conducted in

accordance with approved procedures, Regulatory Guides, and industry codes

and standards; and in conformance with Technical Specifications.

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 components or systems to service; quality control records

were maintained; activities were accomplished by qualified personnel;

parts and materials used were properly certified; radiological controls

were implemeated; and fire prevention controls were implemented.

Work requests were reviewed to determine the status of outstanding jobs

and to ensure that priority is assigned to safety-related equipment

maintenance which may affect system performance. The NRC inspectors noted

that a backlog of outstanding job orders (J0) exists for the Unit 2

process and area radiation monitoring system and for the Unit 2 fire alarm

system.

The following maintenance activities were observed:

. Removal of the Unit 2 emergency diesel generator rotor

(Procedure 2407.44, JO 87750)

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Replacement of Unit 2 emergency diesel generator rotor (JO 86314)

. Replacement of Unit 2 emergency feedwater pump mechanical seal (JO

87707)

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Testing of Unit 2 emergency diesel generator after rotor repair (Work

Plan 2409.23)

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Calibration of Unit 2 emergency diesel generator starting air

compressor pressure switches (JO 83930)

. Repair of Unit 2 service water pump (JO 521326)

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Preventive maintenance en Unit 1 emergency diesel generator

starting air compressor (JO 522319)

. Replacement of Unit 1 service water discharge strainer studs

(JO 70523)

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Repair of Unit 1 source range signal processor (JO 88541) l

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Repair of autostart circuitry for Unit 2 engineered safeguards

features pump room cooler (JO 88901)

! No violations or deviations were identified.

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8. Maintenance Records Review (Units 1 and 2)

This inspection was performed to verify that maintenance activities on

safety-related systems and components were conducted in accordance with

approved procedures and in conformance with Technical Specification

requirements.

A. Records Review

Corrective and/or preventive maintenance records were reviewed for

the following components:

Number Component

2 TIC-4906 Boric acid tank temperature indicator

and controller

RE-3618 Discharge fiume radiation monitor

2XR-8347 Seismic peak recording accelerometer

P39A Boric acid pump

VSFM-1A Reactor building cooler fan motor

CV-7444 Reactor building isolation valve

for hydrogen purge system

2P36C Charging pump

FI-1209 High pressure injection flow indicator

2PT-5012 Safety injection tank pressure

transmitter

PM39A Boric acid pump motor

2M55A Hydrogen recombiner

2CV-3200-2 Containment isolation valve for fire

water system

P35A Reactor building spray pump

2P89A High pressure safety injection pump

2SI-13A High pressure safety injection check valve

CV-1050 Decay heat removal system isolation valve  ;

006 Station battery

2031 Battery charger

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The NRC inspectors' review of these records indicated that:

. Administrative approvals were obtained prior to work initiation.

. Limiting conditions for operation were met while the components

or systems were out of service.

. Approved procedures were used when required.

. Quality control inspections were performed and documented

when required.

. Testing was performed, when required, prior to returning the

equipment to service.

. Maintenance was accomplished by qualified personnel.

. Corrective and preventive maintenance records were retrievable.

. Job orders were properly reviewed by licensee personnel.

Maintenance history at the site is maintained on microfilm with a

computer-based index system. The NRC inspectors found this system to

be awkward to use, requiring considerable skill and experience on the

part of the licensee personnel searching the system for the requested

records. Apparently records have been indexed in an inconsistent

manner, requiring several different types of searches to retrieve all

applicable records. Licensee personnel informed the NRC inspectors

that an improved maintenance history filing system is currently being

developed.

B. Procedures Review

The NRC inspectors reviewed a sampling of the procedures associated

with the corrective and preventive maintenance activities performed

on the components listed above.

The procedures reviewed are listed below:

Number Title

1307.06 006 Quarterly Surveillance

1402.03 Reactor Building Spray Pump Disassembly,

Inspection, and Reassembly

1403.03 Limitorque Motor Operated Valve Inspection

and Setup

1403.08 Reactor Building Cooling Fan Motor

Inspection / Repair and Preventive Maintenance

2304.16 Hydrogen Recombiner Inspection and Electrical

Testing

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2304.56 Peak Recording Accelerometer

2304.64 Boric Acid Tank Instrumentation

2402.03 Disassembly, Inspection, and Repair of 2SI-13A

2402.36 2P89 High Pressure Safety Injection Pump

Maintenance

2405.01 Station Batteries

Points considered during this review included:

. Technical adequacy of the procedures

. Use of inspection and hold points

. Inclusion of testing requirements

. Conformance to licensee's administrative requirements

. Provisions for proper return to service of components

. Consideration of Technical Specification requirements

. Identification of parts and materials

. Consideration of radiological hazards

. Identification of special tools required

. Identification of test equipment required

. Verification of current calibration status for special

tools and test equipment

C. Job Order Tracking

The NRC inspectors reviewed a listing of job orders for corrective

maintenance on safety-related components. This listing, from the

licensee's job order tracking system, included over 2000 job orders

which have been initiated but not completed. About 25 percent of the

listed job orders had been cancelled. Licensee representatives

researched a small sample of the open job orders and found that, in

most cases, the job had been completed long ago; the job order had

been reviewed and filed; but the tracking system had not been

updated. Licensee representatives indicated that a new job order

tracking system is scheduled to be implemented on August 1, 1985.

D. Conclusions

No violations or deviations were identified. Documentation of

reviewed maintenance activities was adequate, but the licensee's

maintenance history and job order tracking systems need improvement.

This is an open item pending the NRC inspector's review of the

implementation of the licensee's revised systems. (313/8513-01;

368/8513-02)

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9. Requalification Training (Units 1 and 2)

The NRC inspector reviewed licensed operator requalification training to

verify that it is being conducted in accordance with the licensee's

l approved requalification training program and 10 CFR Part 55, Appendix A.

i The requirements for the licensee's approved requalification training

program are contained in Procedure 1023.08, " Operations Training Program,"

Revision 1, dated February 12, 1981.

The NRC inspector reviewed the requalification training program to verify

that any changes made to the program since the last NRC inspection were

made in accordance with the approved program. No instances were noted

where program changes were made that didn't meet the requirements of the

approved program.

The NRC inspector reviewed the requalification records for a sample of

licensed operators. The review included the following documentation:

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. Lecture schedules

! . Lesson plans

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. Annual requalification examinations and responses

. Lecture attendance sheets

. Reactivity manipulation sheets

. Annual performance evaluations

. Emergency and abnormal procedures review sheets

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. Weekly requalification quizzes and responses

i The licensee issues a list of abnormal and emergency prceedures to each

operator twice each year. The operator reads all procedures on the list

and signs the sheets indicating that he/she has reviewed the contents of

the listed procedures. During review of the sheets, the NRC inspector

noted that the list used by the Unit 2 operators did not contain all the

appropriate emergency and abnormal procedures. Procedures 2203.10

"Above Normal Hydrogen-Oxygen Concentration," 2203.10 " Natural

Circulation Cooldown," and 2203.14. " Alternate Shutdown," were omitted

from the list. Procedure 2203.10 was initially issued in 1981, and

Procedures 2203.13 and 2203.14 in 1983. Section 3.d of 10 CFR Part 55,

Appendix A, requires each licensed operator to review the contents of all

abnormal and emergency procedures on a regularly scheduled basis.

Procedure 1063.08, " Operations Training Program," states that licensed

operators review the abnormal and emergency operating procedures not less

than twice each year. The failure of the licensed operators to review the

l contents of all emergency and abnormal procedures at least twice each year

is an apparent violation. (368/8513-03)

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In addition to listing emergency and abnormal procedures on the review

sheets, the licensee also lists other items such as emergency plan (EP)

implementing and radiological control (RC) procedures. These EP and RC

procedures are not plant specific, but apply to both units. The NRC

inspector reviewed the listing of the EP and RC procedures for each unit

and noted that the Unit 1 list required procedures to be reviewed that

were not on the Unit 2 list, and vice versa. The NRC inspector discussed

the need for consistency of training for operators on both units with the

licensee. The licensee agreed to perform an evaluation of the consistency

of training between each unit's operators. This item will remain open

pending the completion of the ifcensee's evaluation.

(313/8513-02; 368/8513-04)

Nonshift licensed persnnnel are required to attend lectures during the

requalification year in those areas where they demonstrate weaknesses on

the annual requalification examination. The NRC inspector noted that one

nonshift individual had failed to attend the required lectures during the

requalification year that ended in May 1985. The licensee had identified

the problem prior to this inspection and is in the process of taking

correctivo action. The licensee has established a new program to ensure

that nonshift licensed individuals attend lectures when required. The NRC

inspector will review this program during a future inspection to ensure it

is functioning properly.

10. Exit Interview

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The NRC inspectors met with Mr. J. M. Levine (ANO General Manager) and

other members of the AP&L staff at the end of this inspection. At this

meeting, the inspectors summarized the scope of the inspection and the

findings.

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