IR 05000272/1993024
| ML18100A711 | |
| Person / Time | |
|---|---|
| Site: | Salem, Hope Creek  |
| Issue date: | 11/04/1993 |
| From: | Eapen P, Kenny T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML18100A709 | List: |
| References | |
| 50-272-93-24, 50-272-93-26, 50-311-93-24, 50-311-93-26, 50-354-93-26, GL-89-10, NUDOCS 9311190256 | |
| Download: ML18100A711 (7) | |
Text
U. S. NUCLEAR REGULATORY COMMISSION
REGION I
REPORT/DOCKET NOS:
50-272/93-24 50-311/93-24 50-354/93-26 LICENSE NOS:
LICENSEE:
DPR-70 DPR-75 NPF-57 Public Service Electric & Gas Company 80 Park Plaza - 17C Newark, New Jersey FACILITY:
Salem 1 & 2 and Hope Creek Generating Stations INSPECTION AT:
Hancocks Bridge, New Jersey INSPECTION DATES:
October 5-8, 1993
INSPECTOR:
APPROVED BY:
QI~*
Dr. P. K. Eapen, Chief Systems Section, Engineering Branch, DRS 9311190256 931109 I PDR ADOCK 05000272
- ..
G PDR 1 Ifate
EXECUTIVE SUMMARY The inspector closed a deviation regarding the written status of the Generic Letter (GL) 89-10 program for motor operated valves (MOV) (Section 2.0). The inspector closed two violations: 1) Regarding the altering of torque switch settings without performing an engineering evaluation, and 2) Regarding the integration of lessons learned, both internal and external, into the GL 89-10 program (Section 2.0). The inspector also closed two unresolved items: 1) regarding hydraulic lock potential in the MOV spring pack area and 2) root cause analysis of failed MOV's (Section 2.0).
The inspector also reviewed other areas of enhancements incorporated into the licensee's GL 89-10 program (Sections 3.0 and 4.0).
DETAILS PURPOSE This combined inspection report addresses the open items discussed in the team Inspection Reports 50-354/91-80 for the inspection at Hope Creek on July 15-19, 1991, and 50-272/92-80 and 50-311/92-80 for the inspection at Salem on May 4-8, 1992. Since the first team inspection the Salem and Hope Creek MOV 89-10 programs have been combined into the 11PSE&G Nuclear Department Motor Operated Valve Progra The remainder of this report will discuss this progra As discussed in the Salem report the program at Salem/Hope Creek meets the intent of Generic Letter (GL) 89-10. However, there were open items discussed in these report This inspection report updates PSE&G's progress in resolving the violations, deviation and unresolved items from both report.0 CWSURE OF OPEN ITEMS (closed) Deviation 50-354/91-80-01 This item was opened because a detailed GL 89-10 program was not available on site after January 1, 1991 as stated in PSE&G's submittal, to the NRC, dated August 31, 199 PSE&G now has a detailed GL 89-10 program description in place NC.DE-PS.ZZ.0033(Q)
11PSE&G Nuclear Department Motor Operated Valve Progra The inspector reviewed this program and found it to be consistent with the recommendation of GL 89-10. This item is close (closed) Violation 50-354/91-80-01 This item was opened because PSE&G was altering the settings of torque switches without performing an engineering evaluation (10 CPR 50.59).
In their response to this violation PSE&G committed to:
Complete a review of pre-start up maintenance records for Hope Creek to identify any similar occurrences, and to review Salem's records for similar occurrence The inspector reviewed PSE&G's audit of the Hope Creek pre start-up maintenance records and deficiency reports (DR) that were issued as a result of the audit. The inspector concluded that all MOV's in the GL 89-10 program were reviewed in an appropriate manner. PSE&G also conducted a review of Salem's GL 89-10 MOV's and the results were dispositioned in an appropriate manne *
The root cause of this violation was attributed to inadequate procedural guidance to maintenance personnel. To prevent recurrence, PSE&G has changed the maintenance procedures for Salem/Hope Creek (HC.MD-GP.ZZ-03l(Q) and SC.MDEU.ZZ-0009(Q)) to require a DR be initiated and processed in order to allow resetting torque switches. The DR process requires a 10 CFR 50.59 evaluation to be performed in order to change switch settings. This process also documents the action of torque switch changes. This item is close (closed) Violation 50-354/91-80-02 This item was opened because lessons learned from internal and external operating experience information was not effectively utilized in updating PSE&G's program and procedure *
PSE&G has attributed the cause to inadequate training, especially in the area of personnel not normally in the mainstream of the Vendor Document Control Program (VDCP) and a lack of a clear understanding by Limitorque and MOV ATS of the PSE&G VDCP point of contact that created missed correspondenc Limitorque and MOVATS have modified their mailing lists as directed by PSE&G, to conform to the vendor contract program insuring the proper PSE&G personnel receive pertinent updates to MOV problems for incorporation into the GL 89-10 progra Extensive procedural changes and training documents were reviewed by the inspecto These changes address actions such as: A letter, from the Vice President, to all personnel reiterating the importance of the vendor document control policy; Quality Assurance (QA) audits of the VDCP; Upgrading the training programs regarding document control; and Procedural changes defining the review process for materials received by outside vendors. After completing his review, the inspector was satisfied.
that PSE&G had corrected the information flow system regarding correspondence updates to the MOV program. This item is close (closed) Unresolved Item 50-272/92-80-001 and 50-311/92-80-001 This item has two parts: 1) When this item was opened, PSE&G did not have a program for periodically checking for grease in the spring pack area and they relied on the VOTES diagnostic data to identify spring pack problems, and 2) Three MOV's (11RH19, 12RH19 and 12CS2) had questionable static test data to support operability of the valves.
1)
PSE&G maintains that periodic sampling for grease in the spring pack area will be performed at a maximum of five years on valves that are in less severe or mild environment, and do not have safety functions such as; containment isolation, repositioning for safety systems' operation, or valve failure history greater than or equal to three failures. Otherwise, the minimum is two years. Also, they will check for grease anytime the MOY requires an overhaul for any reason, and if static or dynamic test data show problems in the spring pack area. PSE&G also stated their program is subject to change as information on MOY's is updated at Salem/Hope Creek or in the industry. In addition, whenever spring packs are replaced it is done with spring packs designed to prevent hydraulic loc )
The inspector reviewed the deficiency reports regarding the valves discussed abov All three valves were operable. Two of the valves 11RH19 and 12RH19 have since been dynamically tested after the installation of new spring packs, and passed the tests satisfactorily. The as-found relaxed spring packs that were removed were evaluated as having relaxed due to wear from normal operation This item is close (closed) Unresolved Item 50-272/92-80-002 and 50-311192-80-002 This item was opened when the NRC team identified weaknesses in PSE&G's approach to failure analysis, and the lack of an evaluation of repeated failures of service water valves manufactured by Jamesbur Position paper 24 to the Motor Operated Y alve Program has been updated to discuss the basis for conducting root cause analysi PSE&G conducted an evaluation of the valves (seven per unit) located in the service water systems. The valve manufacturer and PSE&G concluded that the valves are subject to getting silt in the fiber bearing (nomex) causing excessive wear that subsequently causes the valve to bind. The valve manufacturer recommended the fiber bearing be replaced with one made of monel. PSE&G was refurbishing the seven valves in unit 1 during the ongoing outage. Pending the shipment of the replacement bearings, there is also a plan to replace these bearings in the remaining Jamesbury valves, as plant conditions and material availability are favorable. PSE&G will continue testing these valves in accordance with technical specifications. This item is close.0 UPDATE OF THE GENERIC LETTER (GL) 89-10 PROGRAM The Salem report (92-80) of May 4-8, 1992, discussed PSE&G's plans and commitments for additional improvements to the GL 89-10 MOY program. These commitments were discussed in TABLE 1 of the above report. The remainder of this section discusses updates to that table.
6 Scope and Administration of the Program (Section 2.1 of the Salem Report)
PSE&G was to include corrective action requirements for program resolutions in the program standard as required by the QA Progra PSE&G's GL 89-10 program (NC.DE-PS.ZZ-0033(Q)), Section Three now states
"The Manager Nuclear Mechanical Engineering is responsible for the program content and implementation of the program in accordance with the PSE&G Quality Assurance Program." Design Basis Reviews (Section 2.2 of the Salem Report)
PSE&G was to document a review of the design basis parameters other than differential pressure (e.g., flow and temperature).
Appendix five of the GL 89-10 program now addresses flow considerations, and appendix four addresses temperature considerations. The inspector found their content acceptabl.3 MOV Maintenance and Post-Maintenance Testing (Section 2.6 of the Salem Report)
PSE&G was to implement changes to the maintenance program, preventative maintenance and overhaul procedures to identify hydraulic loc The inspector verified that changes have been made to the maintenance program that discusses the potential for hydraulic lock, and how to document and deal with grease intrusion into the spring pack area. This topic is also discussed in Section 2.0 of this repor * *
PSE&G was to justify the use of a 36 month stem lubrication frequenc * PSE&G has reconsidered their position and is now performing stem lubrication every 18 month.0 ADDffiONAL REFINEMENTS TO THE GL 89-10 PROGRAM The Salem report had additional open items within the report that were not discussed in table 1. The following documents the items and PSE&G's changes to the GL 89-10 progra,,
- PSE&G was to develop two procedures: 1) Supporting differential pressure ( dp)
testing of MOV's as part of the response to GL 89-10 for first time testing of MOV's using VOTES [SC.MD-EU.ZZ-0012(Q)]. and 2) A separate procedure designed to provide instructions for the proper installation of VOTES force sensor [SC.MD-EU.ZZ-0015(Q)].
The inspector reviewed the two procedures and concluded that they meet the intent of GL 89-1 *
PSE&G was to clarify "capability margin" as related to as found torque switch setting The inspector reviewed position paper 6 titled, "Capability Margin," formally titled,
"Operability Margin." The paper clarifies the relationship of how torque switch settings relate to the capability of the valv *
PSE&G was to develop a system to provide a data base for MOV information and switch setting PSE&G has enhanced their "Maintenance Management Information System" to provide this data base. The inspector reviewed documentation from computer print outs to verify that the system is functionin *
PSE&G had not completed the evaluation of valves to be in the GL 89-10 progra There were 34 valves left to evaluate at the time of the Salem inspectio PSE&G has completed the evaluation of all the valves at Hope Creek and Salem and now has a complete list that is included in the GL 89-10 progra.1 GL 89-10 Program Completion The HC program will be completed by the spring of '94; completion formally was June '9 Salem was granted an extension from June '94 to fall of '94 for Unit 2, and spring '95 for Unit.0 CONCLUSION This inspection was performed to update the status of the PSE&G MOV program and to close unresolved items and violations. The inspector found that the program is being managed in a responsible manner and that scheduling for testing of GL 89-10 valves is on schedule and in compliance with GL 89-10. The inspector did not witness any testing of valves; however, he noted that dynamic testing was scheduled toward the latter part of the current outage (November). There were no additional open items as a result of this inspection.