IR 05000329/1979020
| ML19260A825 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 10/09/1979 |
| From: | Hayes D, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19260A823 | List: |
| References | |
| 50-329-79-20, 50-330-79-20, NUDOCS 7912030263 | |
| Download: ML19260A825 (8) | |
Text
.
.
'
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT
/
REGION III
Report No. 50-329/79-20; 50-330/79-20 Docket No. 50-329; 50-330 License No. CPPR-81; CPPR-82 Licensee:
Consumer Power Company 1945 West Parnall Road Jackson, MI 49201 Facility Name: Midland Nuclear Plant, Units 1 and 2 Inspection At: Midland Site, Midland, Michigan Inspection Condu ed: September 18-20, 1979 Inspector:
K. R. Nidu
/0/*7@
/
Approved by:
a es, C ef
/D
[79
.
Engineering Support Section 1
//
.
Inspection Summary Inspection on September 18-20, 1979 (Report No. 50-329/79-20; 50-330/79-20)
Areas Inspected:
Installed Control Board 4.16KV and 480V Switchgear and
460V Motor Control Centers including review of related installation records.
The inspection involved a total of 18 inspection-hours onsite by one NRC inspector.
Results: No items of noncompliance were identified in the areas inspected.
One previously identified unresolved matter was upgraded to an item of noncompliance (infraction - failure to control special processes).
1461 188 7 912 030 MD
.
.
DETAILS Persons Contacted Consumers Power Company (CPCO)
- J. L. Corley, Section Head, Inspection Examination and Test Verification E. L. Jones, QA Electrical
- D. R. Keating, QA Group Supervisor
- P. K. Kyner, Electrical QA Supervisor
- D.
B. Miller, Site Manager
- B. H. Peck, Construction Supervisor M. J. Schaeffer, Group Supervisor, Quality Engineering Bechtel Power Corporation (BPC)
- W. L. Barclay, P.F.Q.C.E.
- W. Nielsa, Assistant P.F.E.
- E. Smith, Lead OAE The inspectors also contacted and interviewed other licensee and contractor personnel, including craftsmen, QA/QC, technical and engineering staff members.
- Denotes those who attended the exit meeting.
Licensee Action on Previous Inspection Findings (0 pen) Unresolved Item (329/78-04-01; 330/78-04-01): Electrical raceway system not included on the 'Q' list. Bechtel site QA in a letter dated 21, 1979. NRR in a letter dated August 21, 1979 determined that August cable raceways and raceway supports to be considered safety related and as such must be designed, fabricated and installed under the requirements of the Midland QA program. This item remains open.
(Open) Unresolved Item (329/78-04-02; 330/78-04-02): Class IE components not uniquely identified to assure compliance with 10 CFR 50.55a(h),
(IEEE279-1971 paragraphs 1.0 and 4.22) and IEEE336 paragraph 5.1.1(12).
CPCo has elected to use color as a means of uniquely identifying these components. During the current inspection, the inspector observed that the following are examples of class 1E equipment which were not identified with the respective color codes.
1.
Panels 2C41, 2C42, 2C114 in the safeguards room adjacent to the Main Control Room.
1461 189-2-
-
.
2.
Motor Control Centers (MCC) 2B64, OB65 and IB63 in the Service Water Building.
On September 28, 1979 the licensee informed the inspector by telephone, that CPCo management issued directives to the constru.ctor to identify terminal equipment with appropriate color of the channel it represented.
Pending verification of the implementation this item remains open.
(Open) Unresolved Item (329/78-06-01; 330/78-06-01): The use of G-321-D forms relative to electrical class 1E equipment. Licensee to audit Bechtel Ann Arbor on three items. The licensee has not completed the evaluation.
(0 pen) Unresolved Item (329/78-06-02; 330/78-06-02): Clarification of the proposed Bechtel disposition for Nonconformance Report NCR1207 (con-cerning cable clearances within class IE electrical cabinets Evaluation to QEV-16). Bechtel, in a letter dated August 8, 1978 provided the following information:
1.
TV Board, a fiber board furnished in.028" and.058" sheets is a commercial name for thermally nonconductive insulating material approved by Underwriter's Laboratories and is rated as self-extin-guishing class 94V-0 and contains no Polyvinyl Chloride.
2.
Flexible conduit will be arranged to maintain one inch separation between red and green channels.
The qualification test requirements of Underwriter's Laboratories for class 94V-0 is being reviewed. This item remains open pending completion of this review.
(0 pen) Unresolved Item (329/79-12-05; 330/79-12-05): Pressurizer Safety Relief Valve supplied by Dresser Industries was tested at 1350 psig vs required 2250 psig steam pressure, since steam at 2250 psig was not available for testing. The licensee stated that Babcox & Wilcox (B & W)
is evaluating this matter.
(Open) Unresolved Item 329/79-12-06; 330/79-12-06): The ambient temperature of the Motor Operated Pressurizer Spray Control Valve was specified as 40 C in B & W specification 08-1025000004-03. The inspector determined that Appendix A attached to the above specification specifying that the ambient temperature was for specification 08-1027000003-02 concerning service in the auxiliary building. Valve operator SMB-0-15 is specified in the valve tabulation list titled Reactor Coolant System also attached to the above specification and lists the design pressure and temperature as 2500 psi and 670 respectively. The licensee stated that B & W initially considered only the valve safety related but not the valve operator; however, B & W is re-evaluating this matter and the licensea is expecting a reply from B & W as to whether the valve operator is safoty related.
1461 190-3-
-
.
(Closed) Unresolved Item (329/79-12-07; 330/79-12-07) Documentation on the
'
environmental and seismic qualification on the Motor-Operated Pressurizer Spray Control Valves was not available at the site. The safety class of the motor-operated valve operator appears to be in question as indicated in the above unresolved item (329/79-12-06; 330/79-12-06) which when clarified will resolve this matter. Hence, this matter is considered closed.
(Open) Unresolved Item (329/79-12-08; 330/79-12-08): Paragraphs F ",
-
10.4 and 13.6 of Specification N-151-A(Q) do not adequately specify the environmental conditions the gaskets, sealants and flexible connections should meet without deleterious effects. Bechtel Ann Arbor in a letter dated May 24, 1979 informed the licensee that they indicated in Q & R 031.12 and Test 16 cf the FSAR that they do not routinely require vendors to do specific environmental qualifications for equipment in nonsevere environments. The inspector does not consider this statement acceptable for the following reasons.
Regulatory Guide 1.52 titled Design, Testing and Maintenance Criteria for Post Accident Engineered - Safety Feature Atmosphere Clean-up System Air Filtration and Adsorption Units of Light Water Reactor in paragraph C2e states the following:
In the mechanical design of the ESF system, the high radiation levels that may be associated with buildup of radioactive materials on the ESF system components should be given particular consideration. ESF system construction materials shauld effectively perform their intended function undcr postulated radiation levels. The effects of radiation should be considered not only for demisters, heaters HEPA filters, adsorbers, and fans, but also for electrical insulation, controls, joining compounds,
.
dampers, gaskets, and other organic-containing materials that are necessary for operation during a postulated DBA.
Paragraph C2j of the above Regulatory Guide states in part, "to maintain radiation exposures to operating personnel as low as is reasonably achievable during plant maintenance, ESF atmospheric clean up systems should be designed to control leakage and facilitate maintenance in accordance with the guidelines of RG 8.8."
In pages 3A-8 sheets 1-5 of the Midland FSAR exceptions have not been taken to the above paragraphs.
Pending the outcome of the review of Q & R 031.12 of the FSAR, this item remains open.
(Open) Unresolved Item (329/79-12-10; 330/79-12-10): Corrective action taken by Zach on Bechtel findings in Audit Report No. 25.6.2.
The licensee reported that four findings are still open.
1461 191-4-
,
.
(Closed) Unresolved Item (329/79-18-01; 330/79-18-01): Additional time was requested to investigate whether " plug welds" were indeed made instead of the specified fillet welds. The licensee and contractor personnel could not explain the discrepancy in the inspection records. QCIR-C-304-288W specifies the welding requirements and documents the inspec+. ions performed to verify compliance to the requirements for anchoring essertial 4.16KV switchgear identified as 1A05, IA06, 2A05 and 2A06. Note 13 on the relevant installation drawing C-195(Q) specifies fillet welding; the QCIR specifies plug welds and inspection records indicate that the plag welds were inspecte0 and accepted.
Subsequent to the NRC inspection CPCo identified this matter in NCR M-01-4-9-089 dated August 23, 1979. Entries were made on QAIR-C-304-288W without following procedural requirements.
The iaspector informed the licensee that this unresolved item is escalated to an item of noncompliance, an infraction, contrary to the requirements of 10 CFR 50, Appendix B, Criterion IX for inadequately controlling welding activities.
(50-329/79-20-01; 50-330/79-20-01)
Functional or Program Areas Inspected 1.
Observation of Installed Equipment a.
Main Control Board The inspector observed installed control board panel sections ICIS, IC25, IC30, IC14, IC21, IC22, IC23 and IC24 at elevation 659' in the control room.
1/4" size, 2" long fillet attachment weld at 6" centers, anchor the control board panel sections to embeds on the floor of the control room.
In some instances, the inspector observed questionable clearances between the panels and the embeds which may have exceeded the fit up toler-ances; the inspector verified that in these instances, Field Change Requests (FCRs) were generated and approval was obtained to either " butter" the embed or extend the weld proportionally.
The size of the welds are in accordance with drawing J-201-4-6.
An " Overview Inspection" was performed by CPCo QA on May 30, 1979 to verify the adequacy of welds attaching the control board panels sections IC30 and 2C30 to embeds. The relevant FCRs #J-117, J-118, J-119, J-127, J-131 and J-132 were attached to the inspection check list. No significant findings were documented.
b.
The inspector observed several completed welds attaching cable tray supports in the upper and lower cable spreading room which appeared to be complete, but were not painted. The licensee QA inspector stated that they were cognizant of this matter and that it has been documented in FQA 79 dated September 2, 1979.
This FQA from CPCo requests Bechtel to paint inspected welds in a timely manner.
i 1461 192 t-5-
,
.
.
.
c.
The inspector observed the installation of 480V Load Centers (LC) and 460V Motor Control Centers (MCCs); in particular IB56 and 2B56 at elevation 614' in the auxiliary building.
In all cases, 1/8" size and 2" long fillet attachment welds at 6" centers were specified. The welds appeared to be acceptable.
Nonconformance Report (NCR) #1367 documents instances where the distance between the lengths of the welds exceeded 6"; this NCR was closed after a reinspection concluded that the amount of welds were more than sufficient.
d.
The inspector observed the licensee's personnel verifying the 4.16KV Switchgear components. The circuit breaker was racked out and dimension checks on the stationary contacts were being made. Subsequently, the inspector established that the following procedures were available for such check out.
(1) GPE-08 Revision 0 titled " Checkout Procedures: Medium and low voltage switchgear." Results are documented in a
"Switchgear Test Record" Sheet.
(2) GPE-09 Revision 0 titled " Checkout Procedure: Motor Control Centers & Distribution Panels AC & DC."
Results are documented in a "MCC/ Distribution Panel Test Record" Sheet.
2.
Review of Quality Records The inspector reviewed the following quality assurance records associated with the installation of control board panels, 480V LCs and 460V MCC.
QCIR C304-1011W (9 pages) documents the inspections on the a.
fillet attachment welds anchoring the control board panel sections to the embeds. Weld Procedure Specification (WPS)
PI-A-Lh (structural) was specified; E-7018 type electrode was used.
b.
QCIR 646W-R1 documents the verification of the installation of 460V MCCS IB56 and 2B56 at elevation 614' in the auxiliary building. The installation consisted of welding the MCCS to the channel embeds. The documents indicate that WPS PI-A-Lh (structural) was used with E07018 type electrodes. Nonconfor-mance Report NCR #1367 dated May 31, 1978 identifies that although 1/8" size, 2" long welds on 6" centers were specified, more than 5% of the welds were between 6" and 7" centers. The NCR was closed after a reinspection concluded that the amount of welds were more than sufficient.
c.
QCIR E6.0-3-Revision 1 and E6.0-20 Revision 1 document the inspections performed to verify the installation of 480VLCs, IB18 and 2B18. NCR No. 1748 dated January 9, 1979 identifies 1461 193-6-
,
.
-
.
%
that the seismic qualification of equipment purchased to P0 E-6 has not been documented in a.50.55(e) report. UCR #1875 identi-fies that rodents chewed the insulation on the control wires (Bildon) type 3/C-18) in switchgear IB17 and IB18 and damaged the insulation. Both NCRs are open.
Note:
Inspection Reports 50-329/78-06 and 50-330/78-06 in paragraph la erroneously states that 480V switchgear IB18 and 2B18 were anchored to the embeds with plug welds; that QCIRC304-646W documents that plug welds are acceptable. The 480V switchgear (Load Centers) have been anchored with 1/4" size 2" long fillet welds at 6" centers - not plug welds; the QC1R C 304-646W indicates that the welds are acceptable.
d.
Review of NCR 2175 (1) The subject NCR was initiated on May 8, 1979 and lists a number of cables with one or more of the following defects:
(a) Intermittent loss of paper separator between individual conductors and outer firewall jacket.
(b) Individual conductor insulation is bonded to the conductor; such a condition makes it difficult to strip the conductors to terminate.
(c) Moisture present in the conductor.
(2) Bechtel Project engineer's disposition on July 5, 1979 was to "Use as Is" based on the following:
(a) Loss of paper separator does not affect the dielectric strength of the cable.
(b) Repair individual conductors with bonded insulation as per manufacturer's instructions.
(c) Purge the water from the cables as recommended by the vendor.
(3) The above position was confirmed by the Bechtel Ann Arbor office on July 25, 1979. CPCo did not concur with Bechtel's position to "Use as Is" and in a letter dated to Bechtel requested the following:
(a) Provide a complete and comprehensive analytical study of what, if any, effect the water will have on the tinned copper conductors and the conductor insulating material.
1461 194-7-
,
..
..
(b) Provide objective evidence, the end result of which is a positive statement, that the cable qualifications are not affected because of being subjected to this water.
(4) Bechtel in a TWX to Essex on September 18, 1978 relayed the above request.
In addition, they were r - ' Jested to evaluate the feasability of performing a 14 day water adsorption test (EM-60 Type Test) on a sample of suspect cable currently on hand at Midland and compare the results of this test with those of a new test. The inspector will review the progress on this matter during a subsequent inspection.
Exit Interview The inspectors met with site staff representatives (denoted under Persons Contacted) at the conclusion of the inspection on September 20, 1979.
The inspector summarized the purpose and findings of the inspection. The licensee acknowledged the findings reported herein.
1461 195-8-