IR 05000285/1990005
| ML20033F602 | |
| Person / Time | |
|---|---|
| Site: | Fort Calhoun  |
| Issue date: | 03/06/1990 |
| From: | Barnes I, Stewart R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20033F601 | List: |
| References | |
| 50-285-90-05, 50-285-90-5, GL-89-04, GL-89-4, NUDOCS 9003220146 | |
| Download: ML20033F602 (6) | |
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APPENDIX
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U.S. NUCLEAR REGULATORY COMMISSION L
REGION IV
NRC Inspection Report: 50-285/90-05 Operating License: DPR-40 Docket: -50-285 Licensee: OmahaPublicPowerDistrict(OPPD)
i 444 South 16th Street Mall j
Omaha, Nebraska 68102-2247 l
Fac111t'y Name: FortCalhounStation(FCS)
Inspection At: FCS, Blair, Nebraska Inspection Conducted: January 22-26 and Fe ruary 5-9, 1990
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-Inspector:~
mA 3 - [o - b i
R. C. 5tewart,' Reactor InsFector, Materials Date
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& Quality Programs Section, Division of Reactor Safety
, Approved:
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J-6 - 90
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I. Barnes, Chief Materials & Quality Programs Date Section, Division of Reactor Safety Inspection Summary Inspection Conducted January 22-26 and February 5-9, 1990 (Report 50-285/90-05)--
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' Areas Inspected: Routine, unannounced inspection of the FCS inservice testing (IST) program for pumps and valves. The inspection included the witnessing of surveillance functional testing of pumps and stroke timing of valves. The inspector also reviewed the FCS IST program upgrade status, test
results, and pump and valve trending data.
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Results:
Implementation of the FCS IST program upgrade appeared to be
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consistent with the schedule contained in the licensee's letter (LIC-89-793)
dated October 2,1989, which committed to completion of IST procedure revisions
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and implementation by October 1, 1990.
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Surveillance tests of pumps and valves witnessed by the inspector were observed to be performed with the most current procedure revisions and appeared to be consistent with ASME Section XI Code requirements and the criteria outlined in Generic Letter 89-04.
No violations or deviations were identified.
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9003220146 900312 PDR ADOCK 05000285 Q
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1 DETAILS l
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1.
Persons Contacted OPPD
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- G. Cook, Nuclear Licensing Engineer
- F. Buck, System Engineer, Raw Water and Component Cooling Water Systems
- M. Burggraf. Nuclear Safety Review Specialist
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- J. Chase, Manager, Nuclear Licensing and Industry Affairs
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- R. Jaworski, Manager, Station Engineering
- L. Kusek, Manager, Nuclear Safety Review Group
- D. Matthews, Supervisor, Station Licensing
- K. Morris, Division Manager, Nuclear Operations
- G. Peterson, Manager, Fort Calhoun Station
- W. Phillips, Shift Technical Assistant
- A. Richard, Assistant Manager, Fort Calhoun Station
- C, Simmons, Station Licensing Engineer
- J. Tills, Assistant Manager, Fort Calhoun Station
- D. Trausch, Supervisor, Operations
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- P. Walling, Supervisor, Plant Administration
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- S. W111 rett, Manager, Administrative Services
- S. Lun.dquist, Nuclear Licensing Engineer
- C. Bloyd, Special Services Engineer
- R. Lippy Special Services Engineer
- R. Short, Supervisor - Special Services Engineering
- M. Frans, Lead System Engineer
- G. Gates, Manager. Nuclear Operations Division
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NRC PERSONNEL l
- P. Harrell, Senior Resident Inspector
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- Denotes attendance at the interim exit interview on January 25, 1990.
- Denotes attendance at the exit interview on February 9, 1990.
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l The inspector also* contacted other plant personnel, including operators,
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technicians, and administrative personnel.
2.
INSERVICE TESTING OF PUMPS AND VALVES (73756)
l-2.1 IST Program Status The inspector ascertained from review of the IST program plan that the FCS IST
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program is subject to the requirements of 10 CFR 50.55a(g) and the ASME Boiler and Pressure Vessel Code,Section XI, Subsections IWP.and IWV, 1980 Edition
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through winter 1980 Addenda.
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-3-In a letter dated July 29, 1988, Omaha Public Power District submitted Revision 4 to the pump and valve IST program for FCS. The IST program covers
.the second 10-year testing interval from September 6, 1983, to. September 26, 1993. The NRC staff, with the help of its contractor (EG&G Idaho, Inc.),
evaluated Revision 4 against the requirements of 10 CFR 50.55a(g), Generic Letter 89-04, and the ASME Code,Section XI. The staff's findings with respect
to the review of the licensee's IST program are contained in the safety
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evaluation (SE) dated December 22, 1988, and in a supplemental safety evaluation (SSE) dated August 17, 1989. The licensee is currently in the progress of upgrading the IST program in accordance with commitments contained inIettersdatedMarch 24, 1989 (Lic-89-20), July 3, 1989 (Lic-89-584), and October 23, 1989 (Lic-89-822).
During this inspection, the inspector reviewed the above licensee's program
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change submittals and the corresponding NRC SE and SSE. There were no anomalies noted, nor were there outstanding questions resulting from this It was also obse'ved by the inspector that the current schedule for review.
r IST procedure revision and implementation, outlined in the licensee's letter (Lic-89-793) dated October 2,1989, shows final completion by October 1,1990.
This schedule, which is a part of the FCS overall surveillance test upgrade effort, has been approved by NRR (letter dated January 9,1990, interim relief approval of IST program pumps and valves).
i In discussing the current status of the procedure upgrade effort with the cognizant IST coordinator, the inspector was informed that there are 225 IST procedures involved in the upgrade effort, with higher priority being placed on revising the safety-related procedures that are required prior to the March 1990 refueling outage. Currently, approximately.100 of the 225 required procedure revisions have been completed and issued. The schedules as outlined in the October 2,1989, letter are being met. The inspector was provided an informal procedure revision status for both pumps and valves. The inspector l
had no further questions relative to the IST program status.
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2.2 Test Witness 2.2.1 Raw Water (RW) Pumps (AC-10A,108,100, and 10D) and Discharge Check
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Valves
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During the period January 22-26, 1990, the inspector observed the following IST operability tests conducted on RW pumps and RW pump discharge check valves:
" Category C Valve Inservice Test," procedure OP-ST-RW-3004, Revision 0.
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l Test performed January 22, 1990.
(Backflow test on RW-125 discharge check L
valve for pump AC-10A. The IST test was performed as prescribed by l
Section IWV-3520 of the ASME Code after replacing a spool piece with a new check valve assembly. The test results indicated the check valve seated
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correctly, with no backflow noted.
"Postmaintenance Operability Test Raw Water Pumps," Procedure ST-RW-2,
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Revision 3.
Test performed on pump AC-10A. The test was performed to determine the operability of the raw water pump after installation of the
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-4-i new RW-125 discharge check valve and to establish new basuine reference values. There is a background of problems associated with the erosion and
corrosion of the four raw water pumps and the associated pump discharge
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check valves; this is documented in NRC Inspection Reports: 50-285/89-09, dated March 31, 1989; 50-285/89-39, dated October 30, 1989; and I
50-285/90-02 (issue date pending).
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The test was performed January 22, 1990, 1730 hours0.02 days <br />0.481 hours <br />0.00286 weeks <br />6.58265e-4 months <br />. The test results reflected that the system flow was in the required action range (i.e.,
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4700 GPM versus a required minimum of 5000 GPM for the 2 heat exchanger alignment). The pump was immediately declared inoperable as prescribed by
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Technical Specification 2.4 and ASME Code, Subsection IWP-3230.
(Lower flow was attributed to the added system resistance of the new check valve
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versus the prior spool piecc.)
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r Pump AC-10A, Lift Adjustment. As a result of pump AC-10A being declared
inoperable and in the required action range, corrective action (prescribed by FCS. procedural requirements and ASME Code IWP-3230) was initiated by the cognizant systems engineer. Maintenance Work Order 894824, with the required signature approvals, was instituted at approximately 1900 hours0.022 days <br />0.528 hours <br />0.00314 weeks <br />7.2295e-4 months <br />'
January 22, 1990. Lift adjustments on pump AC-10A were performed in
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accordance with the applicable portions of Maintenance Procedure MM-RR-RW-0001, Revision 1.
As observed by the inspector, work
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activities were conducted in accordance with procedure requirements. Lift adjustment data recorded in the maintenance procedure and observed by the inspector showed total lift available of.199"; an as-found condition of
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.079" impeller clearance; an as-left impeller clearance.015".
A lift adjustment to.015" for the impeller clearance is in accordance with the pump manufacturer's recommendations (Byron Jackson 28RXL, two stage, vertical circulator pumps manual).
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Pump AC-10A, Retest. Following the pump lift adjustment, the above
postmaintenance operability test, procedure ST-RW-2, was rerun as a
prerequisite to declaring the pump operational after maintenance. The
- test was conducted at 2035. hours on January 22, 1990. The inspector observed that the pump met the IST acceptance criteria including a system flow of 5600 GPM with the two heat exchanger alignment.
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The inspector also observed check valve backflow tests performed
January 24-25, 1990, on Check Valves RW-121 and RW-117 (discharge check valves on pumps AC-10B and AC-100 respectively). Although, it was known
that both Check Valves RW-121 and RW-117 were in a degraded condition and that new replacement valves were being installed, the tests were required in order to meet IST program test frequency and Technical Specification 3.0.4 requirements.
The inspector observed that the tests were performed sequentially in accordance with FCS Procedure OP-ST-RW-3004, Revision 0, " Raw Water System Category C Valve Inservice Test." The backflow test performed January 24, 1990, on RW-121 produced test results which indicated a backflow loss of
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approximately 300 GPM.
Check Valve RW-121 was declared inoperable and an
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engineering RW system evaluation was performed. This evaluation, which utilized prior measured backflow loss for RW-117 of 200 GPM, established
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that the RW system was capable of meeting a worst-case design base 4200 GPM.) (5100 GPM available flow versus a minimum required flow of accident.
A backflow test on Check Valve RW-117 (pump AC-10C) was conducted on January 25, 1990, which verified the validity of the engineering evaluation performed on January 24, 1990, regarding an assumed backflow loss of 200 GPM.
- On January 25, 1990, the inspector reviewed the test data results of the
"Postmaintenance Operability Test," Procedure ST-RW-2, on RW Pump 10D, which was conducted at approximately 0500, January 25, 1990. The pump test was prerequisite to determining the pump operational after the pump discharge check valve (RW-115) had been replaced with a new valve.
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Subsequent to the pump test, a backflow test, procedure OP-ST-RW-3004, was performed on Check Valve RW-115. The inspector observed that the test results indicated that pump AC-10D met the previously established acceptance criteria without the need of a impeller lift adjustment and the subsequent check valve test exhibited zero backflow loss.
In addition to observing the above surveillance tests, the inspector verified the calibration status of M&TE test equipment, installed pressure auges, and the two rimary control room RW supply header flow instruments CP-2890 and CP-2891.
By January 26, 1990, the inspector observed that all degraded pump discharge check valves had been replaced with new valves and required IST program surveillance testing completed.
No violations or deviations were identified during the inspector's observation of the above testing activity.
2.2.2 IST Quarterly Valve Stroke Tests Safety Injection and Containment Spray Pump Tests During the period February 5-9, 1990, the inspector observed additional IST surveillance testing as follows:
" Ventilating Air System Quarterly Category A Valve Exercise Test,"
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procedure OP-ST-VA-3001, Revision 0.
The test was performed on February 5,1990, and involved 16 ventilating air systems, IST Category A valves.
In addition to IST program requirements this test was to satisfy,inpart,TechnicalSpecification3.3(1), surveillance. The inspector witnessed portions of the valve stroke testing in progress and reviewed the completed procedure and testing documentation. The inspector l
observed that the test performance and documenting requirements were in accordance with specific procedural requirements.
Surveillance Test, procedure ST-51/CS-1, Revision 55, issued August 16,
l 1989, "SI/CS Pumps and Valves," on February 6,1990. The inspector l
observed portions of the above procedure surveillance tests which included
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-6-safety injection (y injection (LPSI) pumps SI-1A and B; high-pressure low-pressure safet HpSI) pumps SI-2A, B, and C; and containment spray (CS)
pumps SI-3A, B, and C.
The test also included IST functional testing of the related pump check valves, and valve stroke time testing.
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Each pump test was. limited to a minimum recirculation flow from the safety injectionrefuelingtank(SIRWT)andreturn. SIRWT tank static head level and pump discharge pressure were used to calculate the pump differential pressures.
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Since the pump recirculating systems do not contain flow instrumentation, recirculating flow measurements, as required by ASME Section XI Code requirements, are not possible. This has been recognized in NRR approved Relief Requests 3.1.2 - 3.3.2, SER, dated December 22, 1988, wherein the licensee has committed to perform full safety injection system flows during each refueling outage, when instrumented flow paths are available. The initial full flow tests will be performed during the upcoming outage.
During the above quarterly surveillance testing, the inspector observed that the procedure was well detailed in the step-by-step sequences with respect to precautions, engineering safeguards mechanical checks, independent verifications, and allowable ranges of test quantities for pumps and valves.
During the operability test performed on containment spray pump SI-3C, the inspector observed that the pump differential pressure calculation reflected an alert range value which requires an increased testing frequency. This testing result was properly documented in the surveillance procedure.
The inspector had no further questions after reviewing the completed surveillance test results.
No violations or deviations were identified in this area of the inspection.
3.
Exit Interviews Exit interviews were conducted on January 25, 1990, and February 9, 1990, respectively, with those personnel denoted in paragraph 1.
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the inspector summarized the scope and findings of the inspection. The licensee did not identify as proprietary any information provided to the inspector.
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