IR 05000324/1993005
| ML20034E912 | |
| Person / Time | |
|---|---|
| Site: | Brunswick  |
| Issue date: | 02/18/1993 |
| From: | Moore R, Shymlock M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20034E909 | List: |
| References | |
| 50-324-93-05, 50-324-93-5, 50-325-93-05, 50-325-93-5, NUDOCS 9303020075 | |
| Download: ML20034E912 (5) | |
Text
-
...
.
.
..
.
...,.........
- -. - - _ - - -
"k.
UNITED ST ATES
[(g g
f.p NUCLEAR REGULATORY COMMISslON (N
,o
REGION il
S
$
101 MARIETTA STREET, N.W.
- j t
ATLANTA, GEORGI A 30323
% .. v /
... -
FFR 2 21993 Reput Nos.:
50-325,324/93-05 Licensee:
Carolina Power and Light Company P.O. Box 1551 Raleigh, NC 27602 Docket Nos.:
50-325 and 50-324 License Nos.:
DPR-71 and DPR-62 Facility Name:
Brunswick I and 2 Inspection Conducted February 1-5, 1993 Inspector:
h N
a f/7
. Moore Dats Sig'ned j
7b
- 1dN c2 - &-93 Approved by:
'
M. Shymlockifhief Date Signed Plant Systems Section Engineering Branch Division of Reactor Safety i
SUMMARY Scope:
I This routine, announced inspection 'was conducted in the area of observation of electrical maintenance. Activities reviewed included ongoing maintenance,
.
procurement of materials and parts, and modifications accomplished during this plant outage on the emergency diesel generators.
l Results:
In the areas inspected, violations or deviations were not identified. With one minor exception, ongoing maintenance activities were appropriately controlled. The exception was related to the termination of a work task prior to its completion which resulted in the EDG not being returned to the pre-task configuration.
Based on the sample reviewed, adequate measures were implemented to assure the quality of parts and materials used during maintenance. Appropriate design controls were implemented for the EDG modifications accomplished this outage.
9303020075 930222 PDR ADOCK 05000324 G
_ _ - _ _ _ - _ _ _ _ _ _ - _ _
.-
'
-
i REPORT DETAILS j
!
1.
Persons Contacted
i Licensee Employees
!
- M. Bradley,' Nuclear Assurance Department Engineer
- J. Franke, Supervisor, Technical Support
- M. Jackson, Naintenance Manager, Unit 1
,
J. McKee, Manager, Procurement Engineering
.!
- D. Moore, Maintenance Manager, Unit 2
- G. Miller, Manager, Technical Support
- W. Noland, Manager, Operi Lions Support
,
- R. Morgan, Plant Manager, Unit 1 A. Shah, Outage Management & Modifications Engineer i
G. Shampy, Procurement Engineer
'
NRC Personnel
!
!
- R. Prevatte, Senior Resident Inspector
- P. Byron, Resident Inspector
!
- D. Nelson, Resident Inspector
- H. Christensen, Region II, Projects Section Chief
-;
- J. Johnson, Region II, Deputy Director, Division of Reactor Projects.
{
.
- Attended Exit Interview l
Acronyms and abbreviations are identified in paragraph 4.
2.
Electrical Maintenance (Components & Systems) Observation of Work, Work
.i Activities, and Review of Quality Records (IP. 62705)
,
This inspection included the observation and review of maintenance
!
activities on the EDGs. Ongoing maintenance on the EDGs was observed.
A sample of procurement activities, specifically related to the upgrade i
of commercial grade parts and material, was reviewed. Additionally, the i
inspector reviewed the documentation and installation of modifications i
accomplished on all EDGs during this plant outaga, a.
Observation of EDG Maintenance
'l During this inspection, EDG-3 was removed from service for a routine 18 month maintenance and surveillance inspection.
!
Additionally the licensee was inspecting EDG-3 for potential generic problems identified during the 18 month. inspections j
of EDGs-1 and -4.
EDGs -1,
-2, and -4 were functional and i
aligned for emergency operation. The 18 month inspection included inspection of EDG internal and support system components. The number nine journal / thrust bearing was
!
inspected, the flex drive coupling was inspected, the collision blocks' clearances were measured, the alignments
'
of the auxiliary motor driven pumps were verified, and the load control ASCR relay was replaced.
q
. _.
.
..
..
_ _ _ - _ _ - _ _ _ _
_
_
l
-
.
l
The majority of this maintenance was completed in the week previous to this inspection. Actual maintenance accomplished during the inspection included reassembly of the support systems'
i piping and components following the flex drive coupling inspection
!
and the performance of maintenance break-in runs. No significant l
problems were identified by the licensee' during this routine
maintenance activity on EDG-3. The break-in runs were i
discontinued to permit a valve adjustment on the 7-R cylinder.
The break-in runs were to be completed on the weekend following this inspection.
!
l During the break-in runs the inspector noted an exception to j
otherwise adequate work controls. The exception was related to-i termination of a work process prior to its completion.
The. result of this work process error was that the diesel was started with the right bank cylinder instrument ports open, which allowed exhaust gases to be exhausted into the EDG room. The diesel was immediately shut down.
No personnel or equipment hazard existed.
The ports had been opened when the crew entered procedure ENG-513, Maintenance Instructions for Nordberg Diesel Engine Exhaust Tappets and Inlet Lash, revision 4, to adjust the valves on a right bank cylinder.
Shortly after the above task was initiated, the foreman determined that the adjustment had been made previously and terminated the job task. During the process of leaving the ENG-513 procedure, the engine was not returned to its initial configuration with the instrument ports closed, as required by the procedure. This occurrence represented an example of a work control weakness related to terminating a work process prior to its completion.
The licensee initiated a minor adverse condition report on this issue. The licensee's ACR process provided a methodology for
!
investigation, corrective action, and communication of this issue.
to management and the plant staff.
Overall, the licensee's work controls for the EDG maintenance I
during this outage continue to be adequate. Technical and QC support and supervisory oversight were appropriate for the complexity of the maintenance activities. The work control deficiency which occurred was identified by the licensee and entered into the station's corrective action program.
b Materials and Parts Procurement The inspector reviewed a sample of procurement documentation involving commercial grade dedication activity to upgrade parts and materials for use in EDG safety related applications.
Additionally, the inspector reviewed two examples of the direct replacement evaluation process for safety related obsolete parts.
The procurement dedication examples were primarily reviewed for identification of critical characteristics and verification of j
these characteristics by the receipt inspection process. The I
L
- - _ _ _ - _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
!
'
.
=
critical characteristics provided the basis for acceptance of commercial grade parts and material for safety related applications'on the EDGs.
Engineering procedure ENP-33.5, Structures, Systems, Components, and Parts Quality Classification Analysis and Dedication of Commercial Grade Items for Use in Safety-Related Application, revision 7, provided the licensee's guidance for this process.
i The following procurement evaluations and associated receipt inspection documentation were reviewed:
EER 92-0349 Upgrade of Worthington Air Start Compressor
!
Crankshaft EER 92-0308 Upgrade of Non-Q 0-Rings l.
EER 92-0543 Auxiliary Jacket Water Pump falk Coupling Assembly EER 92-0329 Upgrade of Non-Q EDG Turbocharger Exhaust Manifold Adapter EER 92-0517 Upgrade of Drill Rod for Use On Nordberg EDGs EER 92-0420 Upgrade of Non-Q Steam / Moisture Trap Body EER 92-0526 Upgrade of Expansion Joint for Nordberg EDGs In the examples reviewed, the licensee identified appropriate l
critical characteristics to provide reasonable assurance that the l
material or component quality was adequate for the safety related l
application.
The receipt inspection documentation verified that these characteristics were verified by test or inspection.
Two examples of evaluations for direct replacement of obsolete parts were reviewed. DR 91-0057 was-an evaluation of an EDG service water valve which was no longer obtainable as a Q-list component. DR 91-045 addressed the jacket water cooler inlet pressure switchs.
The installed switches were obsolete and would not maintain calibration. The evaluations appropriately compared the original component and system design parameters with the replacement component and adequately verified the design function was achieved by the replacement component.
c.
Modificaticos The inspector reviewed EDG modifications installed during this plant outage. The design change package, including installation and post modificaticn testing documentation, was reviewed. The following design changes were accomplished during the outage:
PM 91-010 Fuel Oil Saddle Tank Level Switch ReplacemenL PM 86-097 DG Improvements (minor indication and control system changes)
PM 90-064 Jacket Water Cooler Service Water Supply Line Replacement EER 92-0262 Reconfigure Exhaust Silencer Exhaust Pipe (completed on EDGs-4, and -3)
_
-._
_.
.
.
.
'
+
..
i 4.
i Appropriate design controls were implemented for the EDG modifications reviewed by the inspector.
)
3.
Exit Meeting i
i The inspection scope and results were summarized on February 5,1993,
!
with those persons indicated in paragraph 1.
Proprietary information is
,
not contained in this report. The inspector described the areas
inspected and discussed in detail the inspection results. There were no
!
dissenting comments received from the licensee.
'
4.
Acronyms and Abbreviations ACR Adverse Condition Report l
'
DR Direct Replacement
,
EDG Emergency Diesel Generator EER Engineering Evaluation Report
_;
IP Inspection Procedure
'
NAD Nuclear Assurance Department OM&M Outage Management and Modifications
!
QC Quality Control
!
,
t
!
f
,
!
,
1 j
!
!
.t
!
!
,
,
!
!
.