IR 05000329/1980030
| ML20002C304 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 11/21/1980 |
| From: | Knop R, Naidu K, Sutphin R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20002C303 | List: |
| References | |
| 50-329-80-30, 50-330-80-31, NUDOCS 8101100013 | |
| Download: ML20002C304 (19) | |
Text
.
U.S. NUCLEAR REGULATORY COMMISSION
-
OFFICE OF INSPECTION AND ENFORCEMENT
l
REGION III
Reports No. 50-329/80-30; 50-330/80-31
'
Docket Nos. 50-329; 50-330 Licenses No. CPPR-81; CPPR-82 Licensee: Consumers Power Company 1945 West Parnall Road Jackson, MI 49201 Facility Name: Midland, Units 1 and 2 Inspection At: Midland Site, Midland, MI; Jackson and Ann Arbor, MI Inspection Conducted: October 7-10, 15-17, and 20-23, 1980 b h' W h d. f Inspectors:
K. R. N 'du
///2//70
.
R. N. Sutphin
// /20/ 80 Approved By:
R. C. K o, Chi
//
O Projects Section 1 Inspection Summary Inspection on October 7-10, 15-17, and 20-23, 1980 (Reports No. 50-329/80-30; 50-330/80-31)
Areas Inspected: Tr.ining records; audit activity; personnel air locks; quality assurance organization; construction schedules; nonconformance reports; on site design activity; electrical components; followup of unresolved and non-compliance items; review of licensee activity regarding I&E Bulletins and Circulars. The inspection involved a total of 68 inspector-hours onsite by two NRC inspectors.
Results: Of the ten areas inspected, no items of noncompliance or deviations were identified.
8102 IocoB =
.<s.
--
.
I
.
DETAILS Persons Contacted Principal Licensee Employees
- D. B. Miller, Site Manager
,
- *H. P. Leonard, Acting Site Project QA Superintendent
,
- *D.
P..
Keating, Section Head, IE & TV
,
- *T. C. Cooke, Project Superintendent
,
,
R. L. Oliver, Senior Engineer, Product Design
- J. N. Leech, Senior Engineer, Safety & Licensing
- W. R. Bird, QA Manager, Midland Project
- G. S. Ridge, Genreal Supervisor, System Protection
- *M. J. Schaeffer, Group Supervisor. Elect. Q.E.
,
- B. W. Margualio, Director, Environmental Services & QA
- R. C. Bauman, Design Production Manager - Midland T. K. Subramanian, MPQAD
- E. L. Jones, IE & TV, Electrical
,
P. Lowe, QA Engineer, Audit J. J. Zabritski, Sec. Hd. Des. & Prod., Environmental & Seismic P. Jacobson, Electrical Engineer J. Pastor, Electrical Engineer W. P. Wandby, Senior Engineer System Protection N. W. Heudershot, Engineering Analyst System Protection E. Steining, Electrical Supervisor, Technical Department G. Johnson, Scheduling Bechtel Power Corporation (Bechtel)
- J. Milandin, Manager of QA
- *
, E. Smith, PFQCE J. J. Gilmartin, PFE M. Elgaaly, APE Midland Project R. L. Rixford, Lead GAE, AA0 - Midland E. M. Hughes, Asistant Project Engineer, Midland S. Grant, Construction Coordinator J. R. Northrup, Weld. Engineer, Materials and Quality Service
"
R. F. Steigerwald, Manager, Material.s and Quality Service D. Chow, Midland Civil D. Yuan, Midland Civil D. J. Lefevre, Midland Civil Struct.
- J. P. Betts, Construction
,
- P. Corcoran, Resident Engineering
,
L. Snyder, Resident Engineering
- E. Newman, Assistant PFQCE l
,
'
- A. McClure, Construction
,
D. Reia, Electrical QA l
l
-2-l l
_
.
W. J. Woolley Company
-
R. A. Maffei, Manager of Engineering USNRC-RIII
- R. Cook, Resident Inspector
,
Other licensee and contractor personnel were contacted during the inspection.
- Denotes those present at an update meeting.
- Denotes those present at the exit interview.
,
Licensee Action on Previously Identified Items (0 pen) Noncompliance (329/78-03-03; 330/78-03-03)
-
The NRC inspector reviewed the following records of training sessions held for Quality Control welding inspectors:
On February 13, 1978 " Training Session on Undersize Fillet Welds" was conducted with approximately 18 attendees.
On March 16, 1978, instruction from PFQCE to all welding inspectors emphasiz-ing visual examination to detect and measure the worst condition in a fillet weld.
On April 16, 1978 two separate training sessions were conducted for about 22 attendees.
NCR 987 dated October 13, 1977 documents several discrepancies in the welds in the Unit I cable spreading room.
Initial disposition dated November
'r, 1977 was to rework the welds to meet the specification requirements. however, this was superceded and corrective action was dispositioned on June 26, 1978 after a reinspection of this NCR and other NCRs. This final report did not expressly state that NCR 987 was closed.
NCR 987 recommends the following two corrective actions:
at Rework for all fillet welds that have coarse ripples, high crowns, excessive concavity or convexity, and where the base metal has been ground and grooved to unacceptable thickness.
b.
"Use as is" for all oversize fillet welds that otherwise conform to the specification.
A weld on No. 82 in Unit 1 lower cable spreading room was identified to be porous and had a crater. During a previous inspection, the inspectors could not determine that this weld was repaired and reinspected. The licensee agreed to reexamine this item and provide additional information.
-3-
l
,
As a result of the above observation, the NRC inspector noted that NCR 987
.
was reopened on March 6, 1980 because the licensee determined that docu-mentation was unavailable on the rework and reinspection. The welds were reinspected, and QCIR C-304-15454, Log 62820 dated February 28, 1980 was initiated to reinspect the welds. The results of the reinspection was documented in NCR 987.
NCR 987 was reopened to correct the findings of the reinspection; the licensee stated that since October 13, 1977 several modifications were implemented which did not match with the October 13, 1977 requirements.
Records indicate that the findings were corrected and reinspected with the exception of three items. These three items were corrected on October 9, 1980 during the current NRC inspection. The NCR 987 is con-sidered closed as of October 10, 1980.
(0 pen) Unresolved (329/78-04-01; 330/78-04-01) -
Cable trays and fittings not included in the safety related item list.
Coupon samples from installed cable trays and fittings were collected and tested. Test reports have not been issued.
(0 pen) Unresolved (329/79-12-05; 330/79-12-05) -
,
A proposal to test the PORV addressing three concerns, namely, leakage, operability, and capacity during discharge of steam, water and two phase mixes. The facility to conduct reliability tests on this valve in addition to the block valve and pressurizer code valve is scheduled to be complete in March 1981; the actual tests will be scheduled thereafter.
(Closed) Unresolved (329/79-12-06; 330/79-12-06)
-
It was previously identified that B&W was reevaluating whether the pressurizer spray control valves were safety related. The licensee informed the inspector that a design change was made introducing an auxiliary spray line for which a new specification is being developed. As this new line is considered safety related, the existing valve is not required to be updated.
(0 pen) Unresolved Item (329/79-12-08; 330/79-12-08) -
It was previously reported that environmental qualification of gaskets and sealants used in HVAC ductwork was not available. Underwriter laboratories in a letter dated September 28, 1970 tested "Hardcast Tape" for flame spread, fuel contributed and smoke developed, and determined it acceptable. A letter from ITT Research Institue dated April 30, 1975 indicates that "Hardcast Tape" was irradiated with cobalt-60 on April 14-16, 1975 and that the irradiated sample was compared with a sample of unirradiated tape; no discoloration, embrittlement, or apparent changes in physical properties were observed.
A certificate of conformance was issued from Minnesota Mining and Manufactur-ing Company that Weatherban No. 1202 was manufactured in strict conformance i-4-
. -.
,
.
--
-
. - _.
..
.
with their standard procedures. Even though this meets the requirement in
.
Section 5.14.1 of Specification 7220-M-151A(Q) Revision 8 it does not address the environmental requirements for the tape.
(0 pen) Unresolved (329/79-25-01; 330/79-25-01)
-
It was previously reported that the installation of cable identified as E0V040A, DAB 6501L, DEV040B and OBB601L did not meet the separation criteria specified in the Bechtel Drawing E7(Q). NCR 2765-SD293 was generated to document this condition. Design Change Notice No. 9 was written against Drawing E-18(Q), designating the wire way in which each channel is to be Interlocks are to be provided to prevent energizing motors from run.
channels A&B simultaneously. Requisitioned spare parts have not been received to modify the existing nonconformance.
(0 pen) Unresolved (329/80-01-06; 330/80-01-07)
-
The following additional information was requested relative to the B&W specification for Nuclear Instrumentation and Reactor Protection System cabinets:
1.
Whether flame retardant requirements for internal cables were imposed.
The licensee received a B&W 1etter dated July 24, 1980 which states in part, "We can advise you that the NI/RPS cabinet wiring insulation is Teflon and is therefore flame retardant. Due to the ordering date of the NI/RPS, our equipment specification did not require flame retardancy and no traceability of the wiring of insulation material can be obtained". The licensee acknowledged that this letter is not a " Certificate of Conformance" for the flame retarding of the cables and is attempting to obtain one.
!
!
2.
Who reviewed the tests and analysis of the isolation devices. During the current inspection, the licensee stated that isolation devices l
(operational amplifiers) used in the Reactor Protection System (RPS)
'
cabinets were tested by B&W and are referenced in the B&W Topical Report 10.003 (see page 7.2-12 FSAR). This portion of the unresolved item is closed.
3.
Whether isolation device circuits" included internal wiring to the isolation devices which will preclude intermingling of protective and
-
control function wiring. The licensee stated that Electro Magnetic Interference (EMI) tests were performed and is referenced in paragraph C page 7.2-20 of the FSAR. This portion of the unresolved item is closed.
!
(Open) Unresolved Item (329/80-15-01; 330/80-16-01)
-
l l
Corrective action taken on 14 audit findings and 9 unresolved items identi-fied in Audit Report M01-55-0 is incomplete. Review of the documents sent by mail subsequent to the conclusion of the NRC inspection indicates that-5-
.
. - -
-
there were communications between the auditor and the auditee and justifies the delay in responding to the corrective action. The inspector discussed some of the responses to the audit findings documented in the final response dated July 29, 1980 with the Corporate QA personnel, including the Director of QA.
It was agreed that the quality of the responses would be improved.
The corrective action taken to the audit findings will be reviewed after completion.
Review of Licensee Action Taken on IE Bulletins (Closed) 75-03 ASCO Solenoid Air-Pilot Valves, Series 8300-C and 8302-C.
-
The licensee letter Serial 1534 dated May 12, 1975 states that these valves have not been used.
(Closed) 75-06 Failure of OT-2 Control Switches. The licensee letter
-
Serial 1673 dated July 23, 1975 states that as of that date no OT-2 switches were used; if they planned to use them in future, they would verify if Westinghouse corrected the design.
(Closed) 76-02 - Relay Coil Failures of GE Type HFA, HGA, HKA, HMA Relays.
Bechtel letter dated May 10, 1976 states that these types of relays are not in the NSS System and that though these type relays may be used in non-safety related systems, it will be ensured that they will not be of the 1969 vintage or earlier models.
(Closed) 76-03 - Relay Malfunctions - GE Type STD relays due to radio fre-quency interference. Bechtel letter dated May 10, 1976 states that these relays are not used at Midland.
(Closed) 76-05 - Malfunction of Westinghouse type BFD relays. Licensee letter Serial 2393 dated May 10, 1976 indicates that these relays are not used in safety related systems.
(Closed) 77-01 Drift in Pneumatic Point in ITE Imperial Relays Catalog
-
J20T3/J13P20 or J20T3/J13P30. The licensee's letter dated June 28, 1977 states that they are not aware that relays of these vintage are used in the Midland plant. The letter states that the majority of the time delay relays
,
l are used on safety-related circuits for alarm purposes only and serve no safety functions and that other time delay relays used in safety-related circuits have a repeat accuracy of 10% or better.
(Closed) 77-02 Failure of latch arrangements of AR relays - The li-
-
censee's letter Serial 4367 dated October 19, 1977 states that these types of relays are not planned to be used at Midland.
(Closed) 77-05 and 77-05A Electrical connector assemblies. The environ-
-
mental qualification will be in compliance with NUREG 0588.
(Closed) 78-05 Malfunctioning of circuit breaker auxiliary contact
-
,
mechanism - GE Model CR105X. The licensee's letter Serial 5427 dated June 12,
!
1978 states that GE Model CR 105X auxiliary contact mechanisms are not used.
-6-
L
.
(Closed) 79-01 Environmental qualification of Class IE equipment. The
-
licensee has committed to NUREG 0588 and these qualifications are subject to review by NRR prior to fuel loading.
(Closed) 79-09 Failures of GE Type AK2 Circuit Breakers in Safety
-
Related Systems. The licensee's letter Serial 7152 dated June 15, 1979 states that a procedure was developed using the guidelines of General Electric Service Advice Letter 175 (CPDD) 9.3.
The inspector reviewed CPC0 Maintenance Procedure 9762.1 dated October 1, 1979 and determined that the procedure contains the recommendations.
(Closed) 779-11 Faulty overcurrent trip device in circuit breakers for
-
Engineered Safety Systems. Licensee's letter Serial 7187 dated June 21, 1979 states that Westinghouse Type DB 50 and DB75 are not used at Midland Units 1 and 2.
(Closed) 79-23 Potential Failure of Emergency Diesel Generator Field
-
Exciter Transformer. The licensee's letter Serial 7848 dated October 29, 1979 states that the primary windings of the excitation transformer neutral are not grounded and are electrically floating. The sustained full-load operation test of the EDG will be performed in accordance with Reg. Guide 1.108 as committed in the FSAR Appendix 3A and Text Abstract 14A.I.42.
Review of Licensee Action Taken on IE Bulletins Re-Identified For Action By NRC Division of Licensing, September 4, 1980 (Reopened)Bulletin 79-21, transmitted to CPC0 on August 13, 1979.
Re:
" Level Measurement Errors Due to Environmental Temperature Effects on Level Instrument Reference Legs".
This is now covered by Request 031.54.
CPC0 letter Serial 9615, GEC 3-80 of October 3, 1980 transmits a request to Bechtel for a review and assignment of responsibility. The inspector will followup to verify that the Bechtel response and assignment of re-sponsibility is accomplished.
(Reopened)Bulletin 80-06, transmitted to CPC0 on March 13, 1980.
Re:
" Engineering Safety Feature Reset Controls". This is now covered by Request 031.55.
CPC0 letter Serial 9615 GEC 3-80 of October 3, 1980 transmits a request to Bechtel for a review and assignment of responsibility.
The inspector will followup to verify that the Bechtel response and assign-i ment of responsibility is accomplished.
j Review of Licensee Action Taken on IE Circulars I
(0 pen) 76-02 - Westinghouse BF (ac) and BFD (de) Relays, For Information and Action. Circular transmitted to CPC0 August 17, 1976. CPC0 inquiry letter dated September 3, 1976 Serial 2725 File 0505.2 transmitted circular information CPC0 Project Engineer to Bechtel Project Engineer. Reply to RIII dated November 17, 1976 Serial 2950 by CPC0 Vice President stated "No l
Westinghouse BF or BFD relays have been installed or are planned for in-stallation in safety related systems". Telephone confirmation notes on
..
-7-l l
!
_
_
'
,
_ _
_
~
l
file dated November 18, 1976 from Bechtel and CPC0 personnel state:
"Not I
,
being utilized in any equipment being supplied for use in the Midland plant, by Bechtel (or vendors to Becht.el). Letter response to CPC0 Serial 2725 to follow". The followup letters were not available for review. The inspector will followup at a later inspection.
(Open) 77-06 Transmitted to CPC0 April 5, 1977.
Re: " Effects of
-
Hydraulic Fluid on Electrical Cables (Synthetic Hydraulic Fluid Has a Deleterious Effect on the Insulation and Jacketing of Electrical Cables)".
A memo on file dated May 11,1977 to CPC0 Project Engineer states "that I
this is another point in favor of demineralized water as a control fluid in EHC System in lieu of hydraulic oil".
This reply is not responsive to the Circular. The inspector will followup at a later inspection.
(0 pen) 79-02 - Transmitted to CPC0 January 16, 1979. Re:
" Failure of 120 Volt Vital AC Power Supplies - Undervoltage Affects Time Delay Relays and (ESF) Engineering Safety Features Buses, Causing Inadvertent ESF Activation". A margin note dated May 4, 1979 on a copy of the January 16, 1979 letter advises that action was assigned to the site manager. No reply on file from site manager. The inspector will followup at a later inspection.
Interest is in method to be used by site manager to avoid undervoltage effect on system.
(0 pen) 79-17 - Transmitted to CPC0 August 14, 1979. Re:
" Contact Problem in SB-12 Switches on General Electric Metalclad Circuit Breakers - Lack of Continuity Thru Contact "a" Switches Shipped August 1, 1978 to July 1, 1979".
On file are CPC0 letters to B&W Serial CSM-0161 of September 17, 1979 and to Bechtel Serial CSM 0167 of September 24, 1979.
B&W response letter CPCO-2541 of October 23, 1979 advises within B&W's scope of supply there components were not supplied with the WI/RPS, ELCAS or trip portion of the CRCDS. No response from Bechtel on file. The inspector will followup at a later inspection.
(0 pen) 79-20 Transmitted to CPC0 September 24, 1979. Re:
" Failure of
-
GTE Sylvania Relay, Type PM, Bulletin 7305, Catalog SU12-11-AC with a 120 V. A.C. Coil, Notch in the Armature Operating Rod Causes Failure to Drop Oat".
On file is CPC0 letter Serial CSM-0178 of October 3, 1979 to Bechtel, requesting response by November 30, 1980. Response letter to CPC0 BLC-8419 of November 6, 1979 advises no GTE Sylvania Relays, Type PM, used or planned for use at the Midland plant. On file is a response letter from B&W of October 23, 1979, CPC0 2541, which references a CPC0 letter CSM-0179 dated 0,ctober 3, 1979. This CPC0 request letter was not available for review.
The B&W response letter addresses both Circular 79-17 and 79-20. There is a comment in the letter, "For your additional information we note that the CRDCS uses an SB-12 auxiliary contact mechanism but not an SB-12 switch.
Letter also states, "Within B&W's scope of supply...these components were not supplied..." Of concern is CPC0 missing letter CSM 0179 to B&W, and the remark "Use of the SB-12 auxiliary contact mechanism but not an SB-12 switch".
(See Bulletin 79-17). The inspector will followup at a later inspection.
-8-
,
,
L
_..
,_....
_ _ _
.
._.
-
.
(Open) 77-16 Transmitted to CPC0 December 13, 1977. Re:
" Emergency
-
.
Diesel Generator Electrical Trip Lock-Out Features, Emphasis is on Testing and Acceptance Turnover".
CPC0 sent letter 4599 to Bechtel December 23, 1977 - no response required. The inspector is concerned with the "no response required" aspect and no acknowledgement on file from Bechtel. The inspector will followup at a later inspection.
(Closed) 77-09 - Transmitted to CPC0 May 27, 1977. Re: " Improper Fuse Coordination in BWR Standby Liquid Control System Control Switches". This subject does not apply to Midland project. This Circular is closed.
(0 pen) 78-08 - " Environmental Qualification of Safety Related Equipment at Nuclear Power Plants". This matter is under review under NUREG 0588.
(Closed) 78-09
" Arcing of GE Size 2 Starters".
Letter from B&W and
-
Bechtel dated October 13, 1980 and August 28, 1978 indicate that these types of starters are not used at Midland.
(Closed) 78-18 - " Underwriters' Laboratories Fire Test".
Bechtel's letter BLC-7046 dated January 23, 1979 states that the fire test referenced above will have little impact on Midland fire barrier installation because a vertical barrier blanket is not one of the methods presently being used and that special attention will be paid to the effects noted by the test if it becomes necessary to have such installation.
(Closed) 79-23 - "Gould Size 3 Motor Starters and Contactors Failed to Operate". This item was also reported as a 50.55(e).
The inspector reviewed a Midland Project testing department memo REM 81-80 GRM 11-80 dated May 12, 1980 stating that the affected parts were replaced in 3 NEMA Size 3 Gould starters under the supervision of a factory representative. A list of MCCs containing Gould NEMA Size 3 starters and disposition of Corrective Action Reoort CAR 0-ANA-E-20 were enclosed.
.
l
-9-L
'
i Section I Prepared by R. N. Sutphin Reviewed by R. C. Knop, Chief Projects Section 1 1.
Functional or Program Areas Inspected a.
CPC0 Quality Assurance Organization The inspector reviewed the organization chart of the revised Quality Assurance organization, effective August 15, 1980, representing a merger of Bechtel, contract, and CPCO QA personnel.
The Site Project QA Superintendent has been transferred to another position at CPC0 in Jackson, MI.
An offer has been made for a replacement.
In the meantime, the QAE Midland Section Head is acting Site Project QA Superintendent. One vacancy has been filled in the QAE Section. CPC0 is actively working to fill other vacancies.
The organization status will be checked for compliance with commitments, b.
Construction Schedules The or checked the status of construction and construction sch, for the overall Project.
No items of noncompliance or deviations were identified.
c.
On-Site Design Activity The inspector met with CPC0 QA personnel and the Bechtel on-site i
resident engineer group supervisor, etc., to determine the extent of on-site design activities.
,
!
'
It was determined that design activity exists in six (6) categories, as follows:
.
l (1) Civil Group (2) Mechanical Group (3) Control Systems (4) Electrical (5) Large. Pipe Hangers (Redesign)
(6) Small Pipe and Hangers l
These design activities include initial design, design changes, l
selection of standard designs, and redesign if installation
interference develops.
l
!
,
l
!
- 10 -
The design activity is controlled by the Bechtel Power Corporation
.
Engineering Department Procedures Manual. The Manual includes three (3) categories of procedures:
(1)
M.E.D.
- Management of Engineering Directives (2)
E.D.P.
- Engineering Department Procedures (3)
E.D.P.I.
- Engineering Department Procedure Instructions (Guides)
Haster lists for manual contents are sent out approximately every six months for checking contents of the manuals. Manual copy No.
81 was assigned to the Bechtel Resident Engineer Group Supervisor.
The index in this copy was dated October 2, 1980.
The inspector reviewed the following selected examples of the manual contents:
(1) MED 2.7-0, Revision 5, August 20, 1980 Engineering Organization (2) MED 4.37-0, Revision 12, February 13, 1980 Design Calculations (3) EDP 4.37, Revision 2, May 27, 1976 and EDPI 4.37-1, Revision 2, November 30, 1979 on " Design Calculations -
Piping Stress Analysir Instructions" Comment: Found 2 of 12 attachments filed out of proper sequence.
(4) MED 4.46, Revision 14, June 23, 1980, " Project Drawings" EDP 4.46, Revision 3, Miy 27, 1976 EDPI 4.46.2, Revision 0, March 11, 1974, " Identification of Progress Prints" Comment: Found a iancellation notice with this instruction filed ahead of the instruction.
Additional review of the Engineering Department Procedures Manual
-
will be conducted at subsequent inspections.
No items of noncompliance or deviations were identified.
2.
Other Inspection Areas a.
50.55(e) Personnel Air Locks The inspector observed the closing of each door of the personnel air locks for Units 1 and 2.
All doors closed in a satisfactory
- 11 -
.
_.
.
_ _.. _ __
.
-
manner and demonstrated that no metal to metal interference existed due to repair procedures accomplished to date.
The inspector attended a meeting at Bechtel in Ann Arbor, M1 with CPC0 personnel to identify and plan action on the remaining items to resolve the matter. They are:
(1) ASME Code compliance (2) Determination of final weld requirements for wrap around fillet welds and stress relief (3) Update of stress report to reflect splice plate repair technique where used, moment and fillet questions, and evaluation of validity of original analysis (4) Drawing record of as-built configuration
,
.i l
-
- 12 -
.
Section II
.
Prepared by K. R. Naidu Reviewed by D. W. Hayes, Chief Engineering Support Section 1 1.
Observation of Installed Electrical Equipment Units 1 & 2 The inspector observed the following electrical equipment for Units 1 and 2 installed at elevation 614' in the auxiliary building as shown on drawing E-532(Q).
a.
125 Volt Station Batteries ID01and 2D01
'G'
Type Exide batteries are installed.
Instructions for install-ing and operating 'G' Type Exide stationary batteries Section 58.11 was available.
Exide Battery division, under Part 21 requirements, believed that an additional isolation bar is required to be added to the battery to isolate, in two increments, the build up of horizontal momentum in a string of cells on a battery rack step during a seismic event.
It is stated that the additional piece is not required for structural integrity, but for isolation of momentum and will not affect the structural integrity of the Class IE battery racks. Licensee plans to install the additional reinforcements prior to fuel loading.
The inspector reviewed the applicable specification E-12 and determined that paragraph 6.3.3 states in part, " Rack frames shall be structural steel angles and the braces shall be flat steel which can be easily bolted to the frames. The rails supporting the cells steel channels and shall have acid resistant insulating channels over them. All necessary bolts, lock washers, nuts, etc. shall be furnished."
Paragraph 8.1.1 of the above specification states, "The racks shall be finished with a minimum of two coats of acid resistant paint.
The NRC inspector informed the licensee that the specification does not address the hardware which holds the seismic Category I battery
.
rack together to be of acid resistant type as required by 10 CFR 50 Appendix A, Criterion 4.
The licensee stated that a NCR was written that as a result of an inadvertant acid spill, portions of the rack were exhibiting corrosion. NRC inspector requested the licensee to provide additional information as to whether the battery rack specifica-tion will be revised to reflect the requirement that the hardware, used to assemble the seismic Category I battery rack, will be
- 13 -
_
__
_
-.
.__
_ _ _ _.
-
. _.
.
compatible with the environmental conditions in the battery room
.
such as acid atmosphere. This is an unresolved item.
(329/80-30-01; 330/80-31-01)
b.
Battery Chargers ID15, ID17, 2D15, 2D17 (1) The installation of the above 125 volt, 300 ampere battery chargers appeared acceptable.
(2) Receipt inspections were performed and documented in Quality Control Inspection Records (QCIR).
(3) NCR M-01-6-0-10 documents that one leg of a bus bar in a transformer broke at the 90 bend. The bus bar is part of the input transformer which rectifies AC to DC.
The licensee's laboratory analysis attributed the cause of the failure to fatigue cracking initiated at the inner bend radius of the
'
bus. The licensee is pursuing this matter with Solid State Controls, Incorporated, the manufacturer and Bechtel, the AE. Management Corrective Action Report (MCAR) 41 was initiated on September 17, 1980.
Bechtel was requested to review reportability per Part 21 requirements.
125 Volt Fused Disconnect Panels ID13, 2D13 c.
l The installation appears to meet the drawing requirements.
d.
125 Volt Panel Board 1D10, 2D20 The installation appears to meet the drawing requirements.
e.
Inverters 1Y30, 2Y30 The installation appeared to meet the drawing requirements.
f.
480 Volt Load Centers IB18, 2B18 The above load centers were installed to establish procedures.
During installation, it was determined that the embedded steel was not long enough to be welded down. Anchor bolts were in-stalled to anchor the last compartment.
-
g.
Main Control Board Panels These panels were manufactured and supplied by Magnetics, Sandy Lake, Pennsylvania. The inspector observed that some of the structural welds in the center section of the panels were un-acceptable to the American Welding Society Code relative to craters, fit-up gaps, etc. The shop drawings were not available to conduct an indepth inspection. The licensee inspected the
- 14 -
-
-
-
-
- -
-
-
-
-
-
.
-
-
-
-
.
-
welds on other panels and issued a Nonconformance Report requesting a reinspection. Bechtel's G321D form (which established the re-quirements for documents to be submitted for review and for the quality records) did not require the manufacturer to submit the welding procedures for review and did not require documentation on shop inspections. Specifically, 321-D Form for 7220-J-201 sheet 1 of 5 indicate that the following was not required:
Material description.
Welding procedures and qualifications.
Weld control rod procedures and verification reports.
Inspection reports of the welds.
Section 4.1.8 of Specification 7220-J-201 - Main Control Board Panels for Nidland, specifies American Welding Society Code (AWS)
D1.1 for welding requirements.
Paragraph 4.2 states "should conflict between status, codes, standards, and specifications I
exist, the more stringent requirements, as determined by the Buyer, shall govern. Such conflicts shall be brought to the buyer's attention in writing, for disposition."
Paragraph 12.1.7 states in part, " Prior to panel shipment, all the items shall be inspected mechanically and electrically, and Seller's routine factory tests shall be made to verify conformance with the requirements of the item under test."
Documents were unavailable on the above during the current in-spection; license agreed to obtain them. The inspector plans i
to review the results of the reinspection of the welds during a
!
subsequent inspection. This item is considered unresolved.
(329/80-30-02; 330/80-31-02)
No items of noncompliance were identified in the above areas.
2.
Review of QA Records The inspector reviewed the following records:
a.
Battery chargers for Unit 2
'
Document package AE0-5301 contains the following documents relative to Unit 2 battery chargers 2D15, 2D17, 2D25, and 2D27 manufactured by Systems Control Inc., Columbus, Ohio.
(1) Material Receiving Report QC1R R-1.00-2670 dated January 23, 1978 indicates no adverse findings.
(2) Battery charger final test reports.
(3) Battery charger temperature tests.
i l
i
- 15 -
t
.
b.
Battery Chargers for Unit 1
Document package AE0-6233 contains the folloiwng documents relative to Unit I battery chargers.
1D15, 1D17, ID25, and ID27:
(1) Material Receiving Report QCIR R-1.00-3177 dated May 5, 1978 indicates no adverse findings other than incomplete documentation.
NCR 1391 was initiated on June 22, 1978 for lack of documentation.
It was closed on October 4,1978 that the documentation supplied was adequate.
(2) Final shipping and packaging checklist.
(3) Battery charger final test reports.
(4) Battery charger temperature tests.
The inspector informed the licensee that paragraph 7 of the c.
specification E-11 for battery chargers specified the following tests:
(1) Wiring checks.
- (2)
Insulation test to ground and between AC and DC.
- (3) No load losses.
- (4) Full load losses.
(5) Efficiency at one half and full load.
(6) Temperature rise test.
(7) Current limit test.
(8) Ripple voltage measurement.
Documentation on the items marked with an asterisk was not available.
NCR 1391 did not specify the exact documents missing; review of the additional documents obtained indicates that the efficiency at one
'
half load was provided. The NRC inspector emphasized that documenta-tion on the tests specified is required to make the documentation complete. Pending review of data on no load and full load losses, this matter is considered unresolved.
(329/80-30-03; 330/80-31-03)
d.
Station Battery Racks - Units 1 and 2 Document package AE0-7455 contains the following documents:
- 16 -
.
A Material Receiving Report QCIR - 1.00-4199 dated October 30,
.
1978 indicates that the two step high seismic racks for station batteries 1D01, ID02, 2D01, and 2D02 were received with no apparent shipping damage, e.
Station Battery Unit 1 Document package AE0-7720 contains the following documents:
(1) Certificate of conformance from Exide Power Systems dated October 16, 1978 that battery ID01 meets all the requirements specified in Specification E-12.
(2) Various test certificates.
f.
Station Battery Unit 2 Document package AEO-7721 contains the following documents:
(1) Certificate of Conformance from Exide Power Systems dated October 16, 1978 that battery 2D01 met all the Specification E-12 requirements.
(2) Various test certificates.
g.
480 Volt Load Center IB18 (1) QCIR E6.0-30 documents the inspections on the installation of 480 volt load center. The QCIR was revised several times to add inspection criteria of QCI E-6.0, Revision 3 through 5.
A review of this inspection necessitated a reinspection.
QCIR E6.0-30 Revision 2 was re-opened and re-inspections will be performed.
(2) QCIR No. 646 W-R1 C-304 documents that the welds anchoring the load centers to the embed were inspected and determined to be in accordance with Notes 12 and 13 on drawing C-195.
The inspector observed the welds and concurred with the inspection results. The licensee agreed to correct the QC1R where it erroneously states that plug welds were inspected instead of circumferential fillet welds.
-
h.
Seismic Qualifications on Main Control Board Panels (1) Seismic Simulation Test Report 43529 indicates that various control room panels were mechanically subjected to vibration tests at Wyle laboratories at Huntsville, Alabama.
The reports indicate that it was demonstrated that the specimens possessed sufficient integrity to withstand, without compromise of structures or electrical functions, the prescribed simulated environment.
- 17 -
_.
_
.
(2) Anamet Laboratories Incorporated, San Carlos, California,
-
performed an analysis on the control panels C11/C21, C12/22, C13/23, C14/C24, and OC10/0C20.
No items of noncompliance were identified in the above areas.
3.
Review of Nonconformance Reports NCR 1750 was generated on January 9, 1979 to identify that the a.
seismic qualification on the battery chargers was not complete.
Management Corrective Action Report was issued and the NCR was closed on August 27, 1979.
b.
NCR 2630 was generated on October 17, 1979 to identify that battery chargers did not have ventilation coverings and therefore permitted dust and dirt inside the cabinets. Covers were installed on venti-lation openings; equipment was cleaned and inspected.
c.
NCR 1593 dated October 19, 1978 identifies that isolation bars have to be installed on batteries as per manufacturer's recomrendations to meet the seismic qualifications. Field engineering disposition was to install the bars after they were received. The NCR is open.
d.
NCR 1834 dated January 23, 1979 identified improper housekeeping in the battery room area.
Corrective action was taken to remove construction material and cover the batteries. Corrective action was completed on March 22, 1979.
NCR 1876 dated February 14, 1979 identifies that the distance e.
between the battery racks 1D02, 2D02, and 2D01 and the adjoining wall is less than 4" specified in E-12-52-01.
Project engineering consulted the manufacturer and was advised that the racks could be as close as 0.5" provided the walls do not deflect more than 0.25".
It was determined that the battery room walls would not deflect more than 0.125" and therefore the installation was considered acceptable.
No items of noncompliance were identified in the above areas.
4.
Review of Equipment Verification Activities The inspector discussed activities related to verification of installed DC equipment and reviewed documentation of the results of tests. The inspector determined the following:
a.
The scope of the system is checked.
b.
Licensee compiles a " System Deficiency List".
c.
Bechtel Construction compiles an " Exception List of Open Work".
- 18 -
_
_
.
d.
For example, the scope of DC system data sheet includes, the battery charger, fused disconnect, DC panel, and battery.
e.
Missing equipment is listed on a Corrective Action Report (CAR);
CAR designates the action party who is to resolve the matter.
f.
Meters are calibrated; in the DC panels, the ammeters were calibrated.
g.
Trip settings are verified; in this case, the magnetic trip on the AC and DC circuit breakers were verified.
h.
Storage verification is performed on applicable equipment; monthly storage report documents the specific gravity and voltage of each cell measured.
i.
Verification procedures exist on standard equipment such as circuit breakers, relays, etc. The relevant procedures are selected and used for the verification.
j.
Verification records for a service water pump included the following:
(1) 4.16 KV cable megger data.
(2) 4.16 KV circuit breaker checkout.
(3) Setting of the relays in the circuit breaker.
(4) Load test on the service water pump including vibration, line currents, etc.
No items of noncompliance or deviation were identified in the above area.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompliance, or deviations. Unresolved items disclosed during the inspection are discussed in Section II, Items 1.a, 1.g, and 2.c.
Exit Interview The inspector met with licensee representatives (denoted under Persons Contacted) for update meetings on October 10, 1980 and October 17, 1980 and conducted an exit interview at the conclusion of the inspection on October 23, 1980. The inspector summarized the purpose and findings of the inspection.
The licensee acknowledged the findings reported herein.
l
- 19 -
!