IR 05000317/1990010

Insp Repts 50-317/90-10 & 50-318/90-10 on 900514-18.No Violations Noted.Major Areas Inspected:Activities Re Engineering Mods

ML20055J320
Person / Time
Site:	Calvert Cliffs
Issue date:	06/15/1990
From:	Carrasco J, Strosnider J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20055J319	List: IR 05000317/1990010 ML20055J318
References
50-317-90-10, 50-318-90-10, NUDOCS 9008020092
Download: ML20055J320 (7)

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U. S. NUCLEAR REGULATORY COMMISSION

REGION I

Report No /90-10 E6;TfB790-10 Docket No License Nos. OPR-53 bPR-69 License Baltimore Gas and Electric Company RD7 ts 2&4, P.O. Box 153h Lusby, Maryland 20M7 Facility Name: Calvert Cliffs Inspection At: Lusby, Maryland Inspection Conducted- May 14-18,199 Inspectors: ef 974 /48 J. E.Dnesco, Reactor Engineer, Materials and tI-/ ' 94 date Processes Se ion, EB, DRS Approved by: 0 f *

J. R. 6trosnider, Chief, Materials and date Processes Section, Engineering Branch, DRS Inspection Summary: Routine Unannounced Inspection on May 14-18, 1990 (Inspection Report No. 50-317/90-10) s

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l Areas Inspected: An inspection was performed of licensee activities related !

to engineering modifications. The modifications included FCR 89-24 which was completed and FCR 89-180 which was in process at the time of inspectio Results: No violations or deviations were identified.

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i 9008020092 000629 "

PDR ADOCK 05000317 Q PDC l

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OETAILS 1.0 PER$0NS CONTACTED 1.1 Baltimore Gas and Electric Company

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• M. Milbradt Compliance' Engineer

• J. Volkoff Compliance Engineer

• G. Detter Nuclear Regulatory Matters C. Cruse kanager of Nuclear Engineering W. Kemper G$ Scheduling

• E. Zumwalt Project Management Unit

• 0. Kennedy Mechanical Modifications

• L. Tucker GS Plant Engineering L. Weckbaugh Gen. Supervisor Electrical Controls

• T. Camilleri Maintenance Superintendent

• R. Szoch, J Principal Design Engineer

• J. Kennedy AGS-Electrical and Instrumentation 1.2 U.S. Nuc_1_ ear Regulatory Commission

• A. Howe Resident Inspector L. Nicholson Senior. Resident inspector

• Denotes those present during the exit meeting held on May 18 1990 2.0 ENGINEERING MODIFICATION 89-24: CONTROL VALVE REPLACEMENT FOR DIESEL BMkIT6R stT&fCE WATER 2.1 Purpose i

The purpose of this modification was to replace existing Masoneilan diaphragm- i actuated butterfly control valves numbered 1-CV-1587, 1-CV-1588, 2-CV-1588 and 2-CV-1587 with Valtek piston actuated, high performance butterfly (H.P.B.)

control valves for safety related servic i

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2.2 Background i

The existing control valves had a swing-through disc design _and a rubber-lined-body. A problem with the rubber lined valve body occurred because during valve operation a vacuum formed in the vena-contracta area of the flow stream immediately downstream of the valve body. This vacuum caused the rubber lining to delaminate from the valve * body and permanently bulg Consequently, when the valve closed, the lining was sheared and the sheared material (portions of rubber) deposited in the diesel generator heat exchanger tube bundle. The failure of the lining _ also caused leakage through the valve. This leakage could cause potential problems with the diesel generator as discussed in cases 1 and

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Case 1 - When the diesel generator is in standby, leakage of the cold service water through the control valve could over cool the lubricating oil, causing piston ring wear and eventually slower start-up time )

Case 2 - When the diesel generator is running, the service water contrel valve is controlled by local, pneumatic pressure across the diesel generator cooler. Thus, any obstruction in the bundle could cause a decrease in the flow rate starving the cooler In order to solve these problems, the licensee initiated a modification by issuing a Facility Change Request (FCR) numbered 89-24. After the feasibility of the FCR was established.-the licensee proceeded with a 10 CFR 50.59 safety evaluatio The safety evaluation determined that the modification prescribed by FCR 89-24 did not constitute an unreviewed safety question.'The inspector found that several potential questions related to structural and mechanical issues were properly addressed in the 10 CFR 50.59 safety evaluation. One being the fact that the Valtek valve is heavier than the existing valve by 39 lbs. This addi-tional weight was reviewed by Bechtel relative to the original piping analysi The other potential structural question was that the Valtek valve for Diesel Generator 11 is supported by a bracket bolted to a concrete masonry wal Calculations performed by Bechtel indicated that the seismic stability of the masonry wall is not compromised. Bechtel had updated the subject concrete block wall calculations to account for the addition of the solenoid valve bracket, These calculations were updated as part of the Calvert Cliffs Block Wall program in response to NRC Bulletin 88-11. Further details of the analyses are presented in section 2.4 of this repor The inspector found no deficiencies in the licensee's safety evaluatio .3 Specification for Butterfly Control Valve The inspector reviewed the licensee's engineering specification No. 584 titled

"High performance Butterfly Control Valves". Attachment D of this specification specifies the Quality Assurance Requirements, section 3.8 of attachment D states,

"B.G.& E or its agent shall perform, at the minimum, the following at the

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supplier's facility prior to shipment: Witness hydrostatic and seat leakage testin . Witness operational testin . Verify the calibration rtatus of the test equipment utilize . Verify qualification status of test personne . Review associated documentatio . Review the packaging and shipping process."

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The inspector reviewed Valtek's certification assembly traveler for the valve and noticed that this document did not have signatures indicating that the customer (B.G.& E.) had performed inspection witnessing of the valve testin After several discussions with the licensee the inspector determined that the licensee's representative was not present at the supplier's facility to witness testing as specifie After the inspector identified to the licensee the lack of surveillance, the licensee presented a NCR, document numbered 5983, dated 7-6-89, which indicated that on-site testing had been performed to substitute for the missed surveillance Thus the licensee's QA program had self-identified and corrected the deficienc The inspector found the corrective action adequat .4 Stress Analysj s Under this particular modification, the inspector reviewed the'following:

(a) Bechtel calculation No. CS-227, titled " Air supply tube routing for i 1-CV-1587." This calculation was performed to verified that the seismic requirements were properly incorporated in the actual design, in accordance with the seismic design criteria M-500. Based on this criteria, the inspector found that all the seismic support spans are within the maximum aowable unsupported span for seismic category 1 tubin !

(b) Bechtel calculation No. C4416, titled " Seismic qualification of solenoid valve mounting bracket for 1-CV-1587 (FCR 89-24)". The inspector, found that all the reactions in the structural members, such as the regulator plate, angle for the condulet, and the 4 x 4 x 1/2 angle for the solenoid valve are within the allowable limit for flexural bending moment. The analysis included the fact that each of the structural components's natural frequencies are greater than 33 Hertz, which make the entire structure rigid relative to the forcing frequencies in a seismic even l

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(c) The mounting bracket transfers the seismic load to the adjacent block wall l No.A24, at elevation 45'-0 in the-Auxiliary Building. The inspector '

reviewed, Bechtel calculation No. C-4204, A24. This calculation demonstrated ;

thn block wall A24 remains structurally adequate considering the new .i seismic loading imposed by this mounting bracke l

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The inspector did not identify any deficiencies in these analyse l 2.5 System Walkdown The inspector walked down the areas affected by modifications 89-24 and 89-180 and noticed that permanent I.D. tags on the solenoid valves were missing. The inspector identified this concern to the licensee who took the proper corrective action in a timely manne l l

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3.0 MODIFICATION FCR 89-180 3.1 Background of permanent Modification Unit 1 and 2 service water systems have the capability of supplying cooling water to the Emergency Diesel Generator (EDG) No.12 which is a swing diesel generator. If a line break occurs on one side of the header, supply and return service water valves (1-CV-1645,1646 and 2-CV-1645,1646) will isolate the affected side of the header by closing, so the unaffected side will continue supplying cooling water to the ED Valves 1-CV-1645 and 1646 receive air supply from the salt water air compressor (SWAC) Nos.11 and 12 common header and 2-CV-1645 and 1646 are supplied from the SWAC Nos. 21 and 22 common header. To ensure the delivery of the air supply to these valves, the air supply tubing is being upgraded to a safety related category. It is important that these air lines remain functional during a seismic event to allow remote operation of these valves so that a service water line break in the common header could be isolate .2 Temporary Modification The licensee has in place a temporary modification (1-89-77) to ensure that a service water break in the common header will not affect units 1 m a 9 Tamporary modification 1-89-77 locks shut 2-SRW-170 and 2-SRW-172. This locked shut condition isolates the unit 2 service water supply at 1-IA-811 and 814. This will enable valves 1-CV-1645 and 1646 to remain open, so that unit I service water will supply cooling water to EDG No.12 or vice versa depending upon the location of the break along the header. This temporary modification will be in I place until the permanent modification described in section 3.1 of this report is completed in its entiret Attachment A of this report shows a P, & I. D. of the permanent as well as the temporary modification 3.3 Ongoing Field Activities The inspector observed the field implementation of the modification and determined ,

that about 80?4 of the 135-feet of piping is complete; and about 50*4 of the !

instrumentation tubing is complete.~This estimate excludes tie-ins to the existing system .4 Stress Analysis #

The inspector reviewed Bechtel calculation No. P2168 titled " Salt water air line to Diesel generator service water control valve". The purpose of this ,

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calculation was to determined the actual maximum stresses on the 3/4 inch salt water instrument airline to the diesel generator service water valve i The inspector reviewed the calculational assumptions, the-analysis method, the computer model and the results. These results show that the support loads are lo !

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The inspector noticed that some conservative assumptions were made to account for unknown values. For example: the loads at the existing XYZ restraint (referred l as nodal point 5 in the mathematical model) were doubled to account for the seismic '

icads from the other side of the restrain ;

No deficiencies in the assumptions or methods of calculation were found, and the !

results show that the piping met all code requirement ;

The inspector also reviewed the functional description for the modification 1 FCR 89-0180 and the 10CFR 50.59 safety evaluation. The latter shows that the modification does not constitute an unreviewed safety questio (

4.0 MANAGEMENT MEETING Licensee management was informed of the scope and purpose of the inspection at -f the beginning of the inspection. The findings of the inspection were discussed !

with the licensee representatives during the course of the inspection and presented to licensee management at the May 18,1990 exit meetin At no time during the inspection was. written material provided to the licensee by the inspector. The licensee did not indicate that proprietary information ,

was involved within the scope of this inspectio !

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i Jtil ' 81990

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Docket No. 50-317 50-318

.i Baltimore Gas and Electric Company ATTN: Mr. George C. Creel Vice President jg'^)

Nuclear Energy Calvert Cliffs Nuclear Power Plant 'i MD Rts 2 & 4, P.O. Box 1535 Lusby, Maryland 20657' l l

Gentlemen: >

Subject: CORRECTION TO COVER LETTER FOR INSPECTION REPORT 50-317;318/90-10 l Please be advised of the fact that the letter dated June 29, 1990 which transmitted the report of the inspection conducted by Mr. J. Carrasco during the period May 14-18, 1990 was in error. _The number of that irspection report

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-l was 90-10 not 90-12 and.90-11 as indicated-in the lette You will Tind the correct cover letter attached. We are sorry for any confu'sion this may have cause !

l No reply to this letter is require

Sincerely,

S'.y.' e,'. E.ip:u4 37:

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M:;y

'Jacque.P. Durr Chief ,

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. Engineering' Bra,nch Division of Reactor *:'

Attachment cc w/ enc 1:

T. Magette, Administrator, Nuclear Evaluations - -

J. Walter, Engineering Division,_ Public Service Commission of Maryk,J G. Adams, Licensing i (CCNPP)

K. Burger,) Esquire, Maryland People's Counsel P. Birnie, Maryland Safe Energy Coalition Public Document Room (PDR)-

Local Public Document Room (LPDR)

Nuclear Safety Information Center (NSIC)

NRC Resident Inspector State of Maryland.(2) e

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C M U S " ~~'0FFICIAL RECORD COPY CC 90-10 ERRATA - 0001. /12/90 cN.qP f h,h I lI

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Baltimore Gas & Electric C . l bec w/ encl:

Region I Docket Room (with r.oncurrences)-

Management Assistant,. DRMA ;w/o encl) ,

R. Bellamy,-DRSS:  :

J. Linville, DRP ,

C. Cowgill, DRP l'

D. Limroth, DRP '

K. Lathrop, DRP M. Conner,'SALP Reports Only i (

M. Callahan, OCA D. Mcdonald, NRR _

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K. Abraham, PA0 (20)'SALP Reportiand (2) All Inspection Reports J. Caldwell, EDO

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RI:DRS ")RI:DRS RI:DRS sco Strosnider Durr 7//P/90 7/l L/90 7////90  ;

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OFFICIAL RECORD COPY CC 90-10 ERRATA - 0002. /12/90

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Jul.181990 t Docket No. 50-317 50-31 ,

Baltimore Gas and Electric Company ATTN: Mr. George C. Creel l Vice President- '

Nuclear Energy '

Calvert Cliffs Nuclear Power Plant MD Rts 2 & 4, P.O. Box 1535

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-l Lusby, Maryland 20657 '

Gentlemen: _

.t Subject: Inspection Report Nos. 50-317/90-10 and 50-318/90-10 (Revised)

This letter refers to the routine inspection. conducted by Mr.-Joseph E. Carrasco of this of fice on May .14' to May 18,1990 -at the Calvert Clif f s Unit 1 Nuclear Power Plant in Lusby, Maryland. Mr. Carrasco discussed the findings of the inspection with Mr. M. Milbradt of your, staff at the conclusion of the-inspectio Areas examined during this inspection are described.in the NRC Region I i inspection report.whichcis enclosed with this letter. Within.these areas,-the inspection consisted of selective examinations of procedures and representative ;

records, interviews with personnel,.and observations-by the inspecto !

Within the scope of this inspection, no violations were observe !

No reply to this letter is require ~

Your cooperation with us in this matter is appreciate *

Sincerely, 0-icir.:1. r! ,: . : "y -

'1 Jacque P. Durr, Chief ,

Engineering Branch  !

Division of Reactor Safety l Enclosure: NRC Region I Inspection Report '.oc. 50-317/90-10 and 50-318/90-10

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0FFICIAL RECORD COPY RT - 0001. if

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