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DESCRIPTION OF EVENT: On November 6,1985, St. Lucie Unit-1 was in Mode 6 for a scheduled refueling. While attempting to lif t the Upper Guide Structure (UGS) out of the reactor vessel (AB), one of the three Lif t Bolts failed. The immediate cause of the failure was insufficent thread engagement and subsequent thread stripping. The failure was discovered at 0620 when the USG was noticed to cocked approximatcly 15 degrees. At 1045 an Unusual Event was declared. An Auxiliary Lif t Rig (ALR) was designed to hold and remove the UGS. At 1400 on November 9, the UGS was level and at 1520 was clear of the reactor vessel. At 1620, the Unusual Event was secured. This is a voluntary report.

CAUSE OF EVENT:

The root cause of the insufficent lif ting bolt thread engagement was due to a deficiency in the maintenance procedure. The maintenance procedure had no precautions nor any steps which checked for full thread engagement.

CORRECTIVE ACTIONS: l All reactor vessel maintenance procedures are being revised to include steps which actually measure lifting bolt thread engagement for all reactor vessel maintenance lif ts on both St. Lucie Units. IE32 ","M"* ''' 8512120444 851206 PDR ADOCK 05000335 S PDR h .- .

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I. DESCRIPTION OF EVENT:

On November 6,1985, St. Lucie Unit-1 was in Mode 6 for a scheduled refueling. At 0600 hours Maintenance personnel commenced lif ting the Upper Guide Structure (UGS) (Figure 1) out of the reactor vessel (AB). By 0620 hours the UGS had been raised approximately six (6) to eight (8) feet above the reactor core (AC) when it was noticed that the UGS was cocked approximately 15 degrees. All operations were secured for further evaluation. Shortly after 0700 hours, an underwater camera inspection revealed that one of the Lifting Rig's (Figure 2) three lift bolts had failed. The immediate cause of the failure was insufficient thread engagement and subsequent thread stripping. The other two lift bolts showed adequate thread engagement and were holding. The resident NRC representative was notified of the event at 0725 hours. At 1045 hours ,an Unusual Event was declared per Nuclear Regulatory Commission request. At 0735 hours, technical assistance was requested in uprighting and removing the UGS from the reactor vessel. The design of an Auxiliary Lift Rig (ALR) (Figure 3) and associated procedures continued until early on November 7. The final design of the ALR consisted of three separate legs - each having a pair of "3-Hooks" connected by steel cables to a hydraulic jack assembly. The hydraulic jack assembly was to be secured to the Lifting Rig's work platform and the "3-Hooks" were to grab the UGS top plate.

On November 8, fabrication of the ALR was complete and ready for load testing. Each leg was load tested separately. The first load test commenced at 1700 hours and was satisfactorily completed at 1808 hours. The other two load tests were completed by early morning, November 9. The ALR was installed on the UGS Lif ting Rig by 0845 hours. At 1345 hours, alternate tensioning of the two ALR iegs which straddled the two good lif t bolts was commenced. The ALR leg which straddled the failed lif t bolt was then tensioned and at 1400 hours the UGS was level. Af ter verifying that the "3-Hooks" were properly i engaged, Maintenance personnel proceeded to raise the UGS. The UGS was clear of ! the reactor vessel flange at 1526 hours and the Unusual Event was secured at 1620 ! hours on November 9,1985. I 1

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II. CAUSE OF EVENT: The root cause of the insufficient lif ting bolt thread engagement and subsequent stripping was due to a deficiency in Maintenance Procedure M-0015, " Reactor Vessel Maintenance - Sequence of Operations". The procedure had no precautions nor any steps which checked the UGS lift rig bolts for full thread engagement. The procedure only required that the lif t bolts be torqued to 50 f t. - Ibs. So when the lift bolt siezed af ter approximately three turns, the personnel torqued it to 50 f t. - Ibs. and assumed that the lif t bolt was properly engaged.

III. ANALYSIS OF EVENT: St. Lucie Nuclear Plant does not consider this event to be reportable; however, due to the widespread interest in the event it was decided to voluntarily report it.

Early in the event the Nuclear Steam Supply System (NSSS) vendor was requested to perform a safety analysis of the event and the proposed recovery. On November 7,1985 the NSSS vendor completed the analysis and the major conclusions were:

1) Should the UGS fall, the core would remain in a coolable configuration.

2) The proposed approach for retrieval of the UGS/lif ting rig assembly did not pose an unreviewed safety question as defined in 10 CFR 50.59.

Therefore, the health and safety of the public was not compromised by this event.

IV. CORRECTIVE ACTIONS:

Maintenance procedures are being revised to include steps which actually measure lif ting bolt thread engagement for all reactor vessel maintenance lifts on both St. Lucie units.

V. ADDITIONAL INFORM ATION:

A. Visualinspection of the UGS has shown no significant damage.

B. This is the first event of this type at St. Lucie.

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U.S. Nuclear Regulatory Commission Document Control Desk Washington, D.C. 20555

Gentlemen:

Re: Reportable Event 85-09 St. Lucie Unit 1 Date of Event: November 6,1985 Defective Procedure Leads to L!f t Rig Failure

The attached Licensee Event Report is being submitted pursuant to the requirements of 10 CFR to provide notification of the subject event.

Very truly yours,

$1/|44 '-s J. W. Williams, Jr. Group Vice President Nuclear Energy

JWW/SAV:dbh Attachment

cc: Dr. 3. Nelson Grace, Region II, USNRC Harold F. Reis, Esquire File 933.1 PNS-LI-85-483/2

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PEOPLE. . SERVING PEOPLE

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