IR 05000316/1980010
| ML17319A616 | |
| Person / Time | |
|---|---|
| Site: | Cook  |
| Issue date: | 08/04/1980 |
| From: | Foster L, Shafer W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML17319A615 | List: |
| References | |
| 50-316-80-10, NUDOCS 8009260308 | |
| Download: ML17319A616 (9) | |
Text
Report No. 50-316/80-10 Docket No. 50-316 License No. DPR-74 Licensee:
American Electric Power Service Corporation Indiana and Michigan Power Company 2 Broadway New York, New York 1004 Facility Name:
Donald C.
Cook Nuclear Plant, Unit 2 Inspection at Donald C.
Cook Site, Bridgman, MI Inspection Conducted:
June 23-27 1980 Inspector: L.. Foster, nspec on Specialist, PAB ate Signed Approved by:
W. D. Shafer, ting Chief, Performance Appraisal Branch ate Signed Ins ection Summa Ins ection on June 23-27 1980 (Re ort No. 50-316/80-10)
licensee's program and documentation associated with the control of centrifugal Charging/Safety Injection Pumps manufactured by Pacific Pump Division of Dresser Industries.
This inspection involved 32 inspector<<hours onsite by one Perform-ance Appraisal Branch inspector.
Results:
Of the areas inspected, no items of noncompliance or deviations were identified.
80osaeo3oE
DETAILS 1.
Persons Contacted Licensee Em lo ees
+D. V. Shaller, Plant Manager
="B. A. Svensson, Assistant Plant Manager
-"E. L. Townley, Assistant Plant Manager
+J. F. Stietzel, QA Supervisor M. Brown, Design Change Coordinator W. Cornell, Maintenance Supervisory Engineer E.
W. Kant, Performance Engineer The inspector also interviewed several other licensee employees, including administrative staff personnel.
NRC Resident Ins ectors
+R. E. Masse, Senior Resident Inspector N. E. DuBry, Resident Inspector
+Attended exit interview.
2.
Exit Interview
~r The inspection scope and findings were summarized on.June 27, 1980 with those persons indicated in Paragraph 1 above.
The licensee was informed that no items of noncompliance or deviations were identified.
3.
Licensee Action on Previous Ins ection Findin s-The inspector did not review previous items of noncompliance or unresolved items, 4.
Unresolved Items No unresolved items were identified during this inspection.
5.
General The Performance Appraisal Branch conducted an indepth review of the licensee's program and performance associated with control of Safety Related Components.
The components selected for this series of Performance Appraisal inspections were the centrifugal pumps manufactured by Pacific Pumps Division of Dresser Industries.
These pumps are used on several safety related systems such as the Charging, Safety Injection, and Auxiliary Feedwater Systems.
The D.
C.
Cook Plant utilizes these pumps in the Charging and Safety Injection System The selection of centrifugal pumps was based on problems encountered with centrifugal pumps as described in NRC Information Notice No. 80-07, dated February 29, 1980, and failure rates reported in the "Nuclear'lant Relia-bility Data System Report" (NPRD). 'ubsequent to IE Notice 80-07, cracks in the stainless steel cladding of a Pacific Pump have been reported by the Zion Plant.
Ob ective and Sco e
The objectives of this inspection were to verify that the component had been designed, fabricated, installed, tested, operated, and maintained as required by applicable specifications; to verify that the licensee/vendor has, and is implementing, controls to ensure that the component fulfillsits design objec-tives and functions; and to determine the effectiveness of the licensee's program associated with Safety Related Components.
The scope of the inspection included a review of purchase orders, specifi-cations, drawings, vendor inspection reports, test results, procedures, modification packages, and maintenance records associated with Pacific Pumps, Serial Nos.
45490-494 and 45605-608.
Interviews with licensee personnel were also held.
Documents Reviewed (a)
FSAR Section 6,
Amendments 16, 21, and 52,
"Emergency Core Cooling Pumps"
~e (b)
D. C. Cook Technical Specification, Section 3/4, "Emergency Core Cooling System"
.
(c)
D. C. Cook, Plant Organization Chart (d)
Technical Specification 6.0, "Administrative Control" (e)
Purchase Order Nos. 546-CAV-103311BN, 54-E-70503B, B46617 (Pump Shaft),
and 595-CAV-216548BN (f) Pacific Pumps Technical Manual Nos.
2600.70 and 1100.4 "Instruction Manual for Installation, Operation and Maintenance of Type JTCH, RLZJ and RLIJ Pumps" (g)
Vendor Instruction Manual No.
2286 dated 4/24/80, Superceding Manual No. 2600.70, 2700 and Supplements 8026 and 8039 (h)
Westinghouse Equipment Specification (E. Specs)
Nos.
677125 and 676428 and other related W Specifications (i)
Westinghouse Motor Installation Manual No. I.I,.3130.Dl (j)
Pump Assembly Foundation and Installation Drawings (k)
Pump Curves Nos. 34617I, 34617R and 34554B (1)
New Performance Curves for Pump Nos.
45490 and 45491 submitted on 10/11/74 (m)
Various correspondence between NRC (NRR), Westinghouse, and the licensee concerning shaft failures (n)
History of type RLIJ pumps at D. C. Cook (2/74 - 4/75)
(o)
History of Type JTCH Pumps at D. C. Cook (6/73 - 10/74)
(p)
W letter No. NS-CE-1536 dated 9/1/77 to NRC "Report of Safeguard Pump Shaft Failures"
(q)
Selected D.
C.
Cook QA Procedures associated with the inspection, installation, operation, maintenance, modification, and testing of pumps (r)
Welder qualification records (s)
Pump Data Performance Sheet Nos. 6.1 and 6.3,
"Performance Tests from 1/4/80 to 6/4/80" (t)
QA Audit Reports dated 3/15/73, 12/26/79, 5/7/80, and 6/18/80 (u)
Procedure Nos.
12 THP-STP-222, OHP-4030.STP.004 and
.005
"Pump Opera-bilityTest Procedures (v)
Maintenance Work Order Nos.
2330, "Install New Rotating Element in Pump 2E"; 24424,
"Diassemble West Charging Pump"; 31766, "Install New Rotor";
and 31910, "Install New Rotating Assembly in Pump 2W",
and other selected work orders (w)
Design Change Installation Authorization No.
RFC DC-12-2485 and asso-ciated review documents concerning the "Addition of Gussets to Charging Pumps to Eliminate Vibration".
Purchase Order Contract and S ecifications The Charging and Safety Injection Pumps for the D.
C.
Cook Plant were pur-chased from Pacific Pumps by Westinghouse (W), the licensee's NSSS supplier.
W also purchased pumps for other licensees under the same contracts and purchase orders.
Each system contains two centrifugal motor driven pumps which are designed to deliver a flow rate of 150 gpm for the charging system and 300 gpm for the safety injection (SI) system.
The charging pump casings are stainless steel clad carbon steel and the SI pump casings are-stainless steel.
W prepared the equipment specifications (677125 and 676428),
supplied vendor inspection, witnessed tests, and performed final acceptance inspections.
W QA Specifications (cleaning, welding, testing, materials, etc.)
were a part of the purchase order requirements.
Several supplements to these orginial purchases have been processed during the contract.
Requirements in the contracts and purchase orders specified that the pumps be fabricated and tested to W specifications plus they were subject to inspection per the November 1968 ASME Draft Code for Pumps and Valves.
Material specifications, testing requirements, inspection require-ments, and other requirements were specified.
Examination of records showed that several additional purchase orders have been let with Pacific Pumps for repair of the pumps.
Due to the Charging Pumps shaft failures as reported in IE Information Notice 80-07, W, Pacific Pumps, and Carpenter Steel Company (the vendor for pump shaft material)
have performed extensive evaluations (W letter and report dated September 1,
1977 to NRC) on the shaft and have changed material, fillet radius, and heat treating procedures to improve notch sensitivity and endurance strength.
Attachment No.
2 to the W letter to NRC specified seven (7) design followup items; however, results of these studies were not available at the D.
CD Cook Plant.
Based on examination of purchase orders, specifications, and related documents it appeared that the technical requirements were adequately specified and met, except for the fillet radius irregularities found by W during the evaluation of the failed shafts.
Corrections of these irregularities.are in progres Surveillance
'and Audits The licensee stated that the pump vendor surveillances and audits were performed by Westinghouse (W) as W had the contract with the pump vendor.
It was noted that W purchased the same Charging/SI Pumps for several plants; therefore, they performed the vendor surveillances and audits.
The licensee stated that their Corporate Office assigned a cognizant engineer to follow work on their pumps and he performed audits and surveillances on W and Pacific Pumps.
The licensee obtained the services of a consultant to evaluate the W Quality Release System.
The inspector did not examine these reports as they are in the Corporate Office and at W offices.
The inspector examined pump performance curves,
'vendor test results, W
quality release forms, correspondence between licensee, W and the vendor, and W certifications that the pumps met requirements.
Surveillances and audits of site activiti'es associated with the charging and safety injection pumps were performed by the site QA group.
This group performed audits and surveillances on storage of pump parts; instrument calibration; procedure implementation; qualification of personnel; work orders; disassembly, assembly, modifications, and Inservice Testing of Pumps.
The site QA group presently have 5 auditors and 7 NDE technicians.
This group audited Pittsburgh Testing Laboratory personnel associated with the last outage.
The reports examined showed the QA group had stopped work on three different occasions relating to instruments out of calibration.
Corrective action had been initiated.
Recei t Ins ection Stora e and Handlin Receipt inspection and storage inspections were performed by the licensee per procedure ME-PP-INSP-M1201.
The inspector examined several receipt inspection reports which utilized check lists to ensure everything was accounted for.
The inspection packages included hold tags, evaluations, and final acceptance tags for the pumps and spare parts.
These reports were documented and filed per procedure.
The licensee had rejected pump No.
45491 on 8/21/71 due to lack of complete documentation.
Hold Tag No. 3884 of 3/ll/71 was issued as the W QC procedure had not been approved by the W engineer.
Hold Tag 969 was issued to account for removal of parts from SI Pump No. 45490.
Other documents relating to storage, rotating pump shafts, housekeeping, lubrication, etc'., were reviewed and found satisfactory.
Installation Testin and Acce tance Documentation associated with the installation, testing, and acceptance of the Charging and Safety Injection Pumps was examined.
D.
C.
Cook procedure No. ME-PP-INSP-1202,
"Pump Installation and Prestart-up" was utilized along with the vendor's technical manual and associated drawings.
The manuals, procedures, and drawings appeared satisfactory.
Inspections were performed utilizing check sheets to ensure that the pumps and accessories were installed
'<<
~
i gt I]
'!
'
Q
~
as specified by procedures and drawings.
Installation and startup data sheets for two charging pumps (1 West and 1 East)
which were tested on 4/18/73 were examined and results met the acceptance criteria..
Maintenance and Modification The licensee had approved procedures to control the maintenance and modi-fication of these pumps.
Procedure Nos.
MHI 5021 rev. 4, dated 10/13/76,
"Maintenance Department Repair Procedure";
MHI-5030 "Preventive Maintenance";
and vendors Maintenance Manual Instruction No. 2286 were the primary tech-nical procedures used.
Procedure Nos. PMI-5020, MHI-2110, MHI-2090, MHI-2160, MHI-2140, plus special instructions were used to control housekeeping, clearances, job order control, cleaning agents, and by-pass of safety functions.
The inspector examined 29 maintenance and repair records which included shaft and rotor replacements to the correction of oil leaks.
Results showed that replacement parts were controlled, work was performed to procedures, and verified by gC.
Job Order No. 31766 of 6/17/77 entailed the installation of a new rotating assembly which required that the vendor service representative be onsite for technical consultation.
Modification of the pumps had been performed both at the site and at the vendor's plant.
Site modifications and design changes were controlled by Procedure PMI-5040, which requires technical review, safety evaluation, and approval by licensee management.
Modifications and design changes proposed and performed by W and Pacific Pumps were not formally approved by the licensee.
These vendor changes normally were generic problems which affect all pumps purchased by the NSSS supplier.
Examples of the above were the change in pump shaft heat treatment, fillet radius,
'welding procedures, threads, and split ring grooves.
The vendor and designer modifications and changes would probably be controlled by W gA specifications; therefore, the licensees do not have control over vendor and designer changes unless the changes affected other plant parameters.
The licensee was installing stiffening ribs to the charging pump end thrust bearing housing per RFC-DC-12-2485 dated March 31, 1980.
This modification is to reduce vibration and the effects are to be evaluated after tests are performed.
The inspector examined correspondence between W, Pacific Pumps, NRC, and the licensee concerning pump shaft failures, investigation of failures, and corrective action proposed and initiated by the vendor (Pacific Pump)
and the designer (W).
The latest information on pump shaft status found by the inspector was dated January 25, 1978, except for the NRC Information Notice 80-07 dated February 29, 1980, and W Technical Bulletin dated March 7, 1978 which place requirements (flushing, minimum flow and NPSH)
on system para-meters prior to operating the charging pumps.
The bulletin also requires more vibration monitoring to determine problems and initiate corrective actions to prevent shaft failure.
The license stated that they were imple-menting the bulletin requirements.
Current information regarding shaft failure status, other investigative results, and final resolution of the problem was not available for review.
A current status or progress report from W and Pacific Pumps concerning the shaft problem needs to be issued by the vendo Inservice Testin (IST)
The licensee has committed to perform IST to ASME Section 'XI-1974 and Summer 1975 Addenda.
Examination of records and discussion with licensee personnel revealed the following:
(a)
Test procedure No.
12-THP-4030-STP-222 has been developed and was being implemented.
(b)
Technical Specification criteria meets the minimum IST requirements
{IWP test program).
(c) If TS requirements are not met, the pump is declared inoperative.
(d)
Pumps are tested on a monthly, quarterly, and yearly schedule as required by ASME Section XI and by Procedure Nos.
2-OHP-4030 STP.004 and 5.
(e)
Test data is reviewed by the Performance Engineering Section.
(f)
Ualues obtained from test programs are used in accessing operational readiness of centrifugal pumps.
(g)
Test information is used by plant management to identify deteriorating equipment and to schedule corrective action.
{h)
Surveillance tests are performed in addition to the IST required tests.
(i)
Pump tests are also performed to meet the State of Michigan requirements.
The inspector examined pump test data from tests performed from 1/12/80 to 6/19/80 and found tests were performed, evaluated, and approved as required.
Final evaluation and approval was by the Performance Engineering Group.
Documentation and Records The purchase orders, W specifications, drawings, vendor's technical manuals, and pump test curves were all available for the inspectors review.
W audits of Pacific Pump Division during the fabrication of pumps was not available for examination; however, W Quality Release Forms, Certificate of Performance, material certification, and witnessed shop performance tests were available.
All correspondence between the licensee, W and Pacific Pump was not available as most of this correspondence is filed at the licensee's Corporate Office.
Correspondence concerning the failed shaft evaluations, corrective action, and immediate remedial action was available; however, a current status report was not available.
Licensee's QA Manual, FSAR, TS, procedures, and other instructions were available; modifications, repair, and maintenance information was in folders Nos.
PP-50 and
and test data was filed in the performance engineer's office.
Results of documentation and records reviewed showed that the licensee (plant,site) is documenting and keeping records as required by procedure.
Res onsibilit ualification and Trainin Personnel interviewed appeared to be qualified and knowledgeable of their responsibilities and procedures associated with Safety Related Components.
QA auditors, NDE technicians, and welders training appeared satisfactory.
Maintenance and other personnel had been given indoctrination training, training in use of clearance permits, rework permits, tool control and the use of other procedures.
Training on pumps had been given by the vendors representative.
An employees training manual was being utilized and provided requirements for each mechanic 'prior to promotion.
The inspector was informed that the licensee's maintenance training program was periodically reviewed by the maintenance superintendent.
16.
Crackin in Pum Casin Claddin (Zion Plant)
The licensee was notified of a reported crack in the stainless steel cladding (reported to RIII by Commonwealth Edison on January 14, 1980) of a Zion Plant Charging Pumps (Type IJ) manufactured by Pacific Pump.
The crack was found during RT examination of the pump suction end plate.
Investigations by Commonwealth Edison, Pacific Pump, and Westinghouse revealed the crack extended through the stainless steel cladding but not into the parent metal.
Additional examinations showed a slight penetration into the parent metal.
Probable cause (as reported)
was the manufacturing technique used to apply the cladding around a sharp inner corner.
The licensee was advised that the NRC staff is presently reviewing this item, and Region III would follow this problem at the D.
C. Cook Plan f