IR 05000354/1985011
| ML20126J295 | |
| Person / Time | |
|---|---|
| Site: | Hope Creek  |
| Issue date: | 05/23/1985 |
| From: | Alba A, Eapen P, Napuda G, Oliveira W, Racho E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I), PHILIPPINES |
| To: | |
| Shared Package | |
| ML20126J251 | List: |
| References | |
| RTR-NUREG-0737, RTR-NUREG-737, TASK-1.G.1, TASK-TM 50-354-85-11, NUDOCS 8506100550 | |
| Download: ML20126J295 (10) | |
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U.S. NUCLEAR REGULATORY COMMISSION
REGION I
Report No.
50-354/85-11 Docket No.
50-354 License No. CPPR-120 Licensee:
Public Service Electric and Gas Company 80 Park Plaza - 17C Newark, New Jersey 07101 Facility Name: Hope Creek Generating Station Inspection At: Hancocks Bridge, New Jersey Inspection Conducted: April 8-12, 1985 Inspectors:
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G./Napuda, Lead Reactor Engineer d' ate Sh$
1. Ofiveira, Reactor Engineer
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d4te GL om slis~ler A. Alba, Reactor Engineer
' date N
Y J /5" E.Racho,PhilippingAtomic dat'e Energy Commission Approved by:
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Dr. P. K. Eapen, Chief,
' date l Quality Assurance Section, 08, DRS Inspection Summary:
Routine unannounced inspection of April 8-12, 1985 (Report No. 50-354/85-11)
Areas Inspected:
Quality Assurance Program for pre-operational and startup i
testing including QA/QC overview and interfacing activities.
The inspection involved 114 inspector hours by three region based inspectors.
Results:
No violations were identified.
One unresolved item was identified in preventive maintenance instructions (paragraph 3.3).
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8506100550 850604 PDR ADOCK 05000354 G
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DETAILS 1.0 Persons Contacted Public Service Electric and Gas Company (PSE&G)
- A.~ Barnebei, Principal Quality Assurance Engineer (QAE)
- G. Champion, QAE J.'Cicconi, Startup Manager
- J. Fi sher, QAE
- C. Fuhrmeister, Lead QAE
- A. Giardino, QA Manager J. Hagan, Operating Engineer
- C. Jaffee, Startup Engineer
- S. La Bruna, Assistant General Manager Operations
- E. Logan, Site Manager T. McLoughlin, QAE Operations
- M. Metcalf, QA Startup Engineer W. Mokoid, Senior Maintenance Planning Supervisor
- M. Rosenweig, Nuclear QA Engineering and Procurement Engineer
- J. Ruckt, Maintenance Engineer Bechtel Construction Incorporated (BCI)
- W. Cole, Lead Site Quality Control Engineer (QCE)
G. Feenstra, Public Service Startup Group (PSSUG) Group Leader
- W. Goebel, Assistant Project Construction QAE P. Goguen, Assistant Project Engineer
- G. Goldsmith, Project Engineer
- 0. Long, Field Construction Manager
- W. Mourer, Ccnstruction Manager Stone and Webster Engineering Corporation (SWEC)
R. Donnellon, Preventive Maintenance Supervisor United States Nuclear Regulatory Commission
- R. Blough, Senior Resident Inspector
- Denotes personnel present at exit meeting.
The inspectors also interviewed other site personnel.
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2.0. Startup Test Program 2.1 Requirement / References Hope Creek Generating Station (HCGS) FSAR Chapters 14 and 17
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Quality. Assurance Instruction (QAI) - 1, Rev.
5, Hope Creek
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Quality Assurance Organization
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QAI 2-11, Rev. 3, QA Program for Phase I and 2 Startup Startup Administrative Procedure (SAP)
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3, Rev.
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Bechtel/Public Service Startup Interface Activities SAP No. 6, Rev. O, Startup Quality Assurance Program
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SAP No. 9, Rev. O, Corrective and Preventive Maintenance
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-SAP No.-10, Rev. 8, Startup Deviation Report Program 2.2 Program Review The inspector reviewed the documents in paragraph 2.1 and determined that the licensee Preoperational Test Program, Phase II, has been established for the: (1) conduct of testing including qualification of startup personnel; (2) tracking of ' test deficiencies; (3) test documentation; and (4) the authorities and responsibilities of individuals or groups to manage these activities.
2.3 Program Implementation and Findings The Public Service Startup Group (PSSUG) consists of approximately 250 -technical and 20 non-manual personnel, of which 20 are PSE&G personnel.
PSSUG is responsible during the Preoperational Test Program Phase II for:
Directing all activities for Initial System Operating Phase.
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The activities include the operational energization of systems, run in of pumps, verification flushing and chemical cleaning of piping, and implementation of programs for preventive main-tenance (PM) and system lay up.
Performing all activities in the Integrated Testing Phase. The
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activities include the preoperational tests, complete baseline date for inservice inspections, finalize the operating and surveillance procedures, establish access control, accomplish testing and operator. training, applicable to the preoperational test program and related to BWROG response to NUREG-0737, Item I.G.I.
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4-The inspector observed the following PSSUG activities:
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Preparing (grooming) the Reactor Water Cooling System (RWCU)
for _ continuation of system flush.
Flushing was stopped until the demineralizer water supply was replenished.
Determining the cleanliness of a section of the Chilled Water-
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System by reviewing the flush cloth against GTP 1, Flushing and Cleaning criteria.
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Performing Startup Change Request (SCR) E-701 regarding wire check of MOV motor overload bypass circuit channel.
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Checking the control wiring of Fan AVH-304 in accordance with TPK-0031 for'the Auxiliary Building HVAC Control Room.
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Performing logic test to satisfy Colt Pielstik (vendor) test was in accordance with DTP-KJ-0001 for the emergency diesel genera-tor (EDG).
Step 7.6.1.7-of the test failed because the motor operated potentiometer was set too high on the governor and the governor caused the EDG to surge.
It was being investigated under Work Order (WO) 85-03-27-0145 which references generic work package (GWP) MD-22-001.
No violations were identified.
3.0 Preventive Maintenance 3.1 Requirements / References Maintenance Department (MD)-AD-22-010Q, Rev.
O, Department
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Preventive Maintenance Program.
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Startup Administrative Procedure (SAP) No. 3, Rev. 3, Bechtel/
Public Service Startup Interface Activities SAP No. o, Rev. O, Startup Quality Assurance Program
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SAP No. 9, Rev. O, Corrective and Preventive Maintenance
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SAP No. 10, Rev. 8, Startup Deviation Report Program
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3.2 Program Review The; inspector reviewed the documents in paragraph 3.1 and determined
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that the _ licensee has established a Preventive Maintenance (PM) Pro-gram ' that provides for:
(1) receipt of and responsiveness to PM inquiries, i.e., information report sheets; (2) thorough evaluations where the sources for the evaluations include controlled vendor data;
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(3) PMs to be documented including justification for the PM action;
.(4) PMs to be distributed and maintained current; and (5) delineating
.the responsibilities and authority of the PM Group.
3.3 Program Implementation and Findings The PM Group consists of a supervisor and maintenance engineers.
The Group has been in existence for four months and reports to the Maintenance Engineer.
The inspector observed or reviewed the following PM activities:
PM package for the Deluge valve for the fire protection system.
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The result of the PM evaluation was to rebuild the. solenoid.
The package contained the -backup material including vendor information to support the PM action.
PM package for a Deepwell pump solenoid valve.
The results
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were to replace the biodegradable parts of the ASCO solenoid valve.
Rotation of the shafts of two stored pump and motor units (Items
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0814 and 00723).
The shafts were rotated in accordance with instructions provided to the maintenance personnel.
Bechtel Maintenance Action Cards (MACS) are provided to the li-
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censee after turnover of the system or subsystem. The cards are
.used as is (rolled over) or reviewed by the licensee including the PM Group. Though this is an interim action, until all main-tenance actions are licensee controlled, the licensee assured the inspector that continuity of the PM actions will be main-tained.
This was demonstrated in the review of Service Water System MACS by the PM Group.
The inspector observed a scheduled (183d) preventive inaintenance
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action of a stored chilled water circulating pump motor (Item 200655).
The Bechtel maintenance action card (MAC) required,
" Remove grease drain plugs and add minimum amount of Unirex N2 to purge motor bearing cavity". The maintenance mechanic inter-preted the action to simply add grease until grease appeared at the drain plug.
When the mechanic saw that he had used more grease than expected in both motor bearing cavities, without any grease appearing at the drain, he notified his supervisor. The inspector investigated the matter and found out that the motor k
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had been greased on October 11, 1984. The interpretation at that time was add two " shots" of grease into each cavity.
The PM group conducted an engineering review and found that action by the Maintenance Department to continue adding grease until it appears at the drain plug was correct. The PM group also recog-nized the instructions were vague and is revising their lubrica-tion manual. _ The Maintenance Department is preparing an advance notice to their personnel on greasing motors.
The licensee agreed to perform an engineering review / analysis of the MAC cards and ensure that other special instructions in the cards are not vague. This is an unresolved item pending resolution by the li-censee and future NRC review (50-354/85-11-01).
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Plant Tours and System Walkdowns 4.1 Mechanical System 4.1.1 Reference / Requirements Reactor Butiding Service Water Piping Above El 102' System
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Isometric 1-P-EA-04, Revision 10.
Reactor Building Service Water System EL 77'
System
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Isometric 1-P-EA-03, Revision 9.
Intake Structure Service Water Strainers Backwash and
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Traveling Water Screen Supply System, System Isometric 1-P-EA-06, Revision 8.
Service Water Strainer Backwash Line/ Intake Structure
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Fabrication Isometric 1-P-EA-027, Revision 5.
Service Water Intake Structure Unit No.
1, Fabrication
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Isometric 0-P-EA-011, Revision 7.
4.1.2 Walkdown and Findings The inspector walked down portions of the station service water-system (SSWS). These portions of the SSWS consisted of areas of piping between the safety auxiliary cooling system (SACS) heat exchangers B2E201 and B1E201 and SACS heat exchangers AZE201 and AIE201. The inspector also walked down piping from the SACS heat exchangers to the reactor auxiliary cooling system (RACS) heat exchangers BE217 and AE217 up to and including valve 453 on line 24" - HYC -073.
The final walkdown consisted of portions of piping in the service water intake structure between service water pumps AP502 and CP502.
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The= inspector verified that the as built configurations corres-
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(P&ID's),_ fabrication. isometrics, (fab IS0's) and system iso-metrics.
All components were readily traceable.
-No violations were identified.
4.2 Electrical System 4.2.1 References / Requirements
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Drawing #E-0006-1, Revision 3,
Single line meter relay
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diagram 4.16 kV class IE power system.
Drawing- #M-10-1, Rev.
O, Piping and Instrumentation
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Diagram Station Service Water System.
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Drawing #7374-5, Rev.
5, Shutdown Control Panel 10C399, Section "0" Drawing #E-0208-0, Rev.
9, Electrical Schematic diagram
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4.16 kV circuit breaker control station. service water pump.
Termination and Jumper document T/A Report.
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-4.2.2 Walkdown and Findings The inspector walked down portions of the Station Service Water
. System. The walkdown consisted of examination of. the instrumen-
.tation of the remote shutdown. panel (10C399), relay panel and control panel in the control room.
Checked selected electrical
. terminations in the shutdown. panel against termination and jumper documents.
Also, the inspector reviewed electrical wiring schematics and verified the as built configurations corresponded to the appropriate instrumentation drawings.
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No violations were identified.
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i-4.3 Observation of Testing 4.3.1 Emergency Diesel Testing A QC inspector assigned to monitor the " vendor acceptance testing"
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of the Emergency Diesel was accompanied during a portion of his duties. It was noted that in excess of 20 "on-the-spot" changes had been made to procedure DTP-KJ0001, Diesel Generator KJA "D" Preliminary and Initial Loaded Operation Under Direction of the Vendor, Rev. O, with the test only partially completed.~ Dis-cussions were held with the cognizant electrical engineers, lead test engineer and Supervisor-Start Up QA with respect to electri-
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cal acceptance criteria changes.
Various electrical diagrams, g
schematics and correspondence between the licensee and manufac-turer were reviewed to verify that a number of changes involving voltage parameters were based on sov.1d technical reasons.
The licensee management acknowledged the inspector's statement of concern, that the potential of large buildups of such changes during testing could interfere with evaluations of test validity
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and results.
No violations were identified.
4.3.2 Electrical Testing The inspector accompanied start-up QC personnel to witness preoperational tests.
He observed equipment and instruments and interviewed test engineers, technicians and QC inspectors.
Personnel involved were knowledgeable regarding test procedures, equipment status and individual responsibilities. The following tests were observed:
"Movats" testing of valve 1-KL-HU-51268
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AKR30 Breaker Test
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The tests were performed in a well-controlled manner and in conformance to procedures. Test results were reviewed and found to be in accordance with the acceptance criteria.
No violations were identified.
5.0 QA/QC Overview 5.1 References / Requirements ANSI /ASME N45.2.6-1978, Qualifications of Inspection, Examina-
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tion, and Testing Personnel for Nuclear Power Plants QAI 2-7, Surveillance Program, Rev. 0
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QAI 10-3, Surveillance Program, Rev. O
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QAP 1-1, Nuclear Operational Quality Assurance Organization,
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Rev. 2
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QAP 1-5, Nuclear Quality Assurance Orientation, Training and Certification, Rev. 1-QAP 6-1, Quality Assurance Audits, Rev. 2
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Applicable procedures in paragraphs 2.1 and 3.1
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5.2 Program and Implementation Review The procedures listed in 5.1 were reviewed, discussions and inter-views were held with personnel, various activity logs and reports were reviewed, and QA/QC personnel were accompanied during their duty tours.
The foregoing was to determine the level of QA/QC overview efforts, adequacy of personnel qualifications, appropriate scheduling and planning, and satisfactory staffing. QA/QC activities were also observed during the two walkdowns discussed in paragraph 4.
5.3 Findings The licensee has developed and is implementing a Hope Creek Transition Plan 1984 that outlines the evolution into an
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organization - for the operation and support of the facility.
This plan includes the time table for assimilation of the construction QA/QC organization into the Nuclear Quality Assurance organization of the Nuclear Department.
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The. monitoring - of pre-operational and start-up testing has been assigned to a QA Start-up group within the construction QA organiza-tion and it will monitor - these. activities to their conclusion.
In addition to seven QA Engineers, this group also has a QC unit of two supervisors and approximately seventeen engineers / inspectors. Duties of this group include surveillance of ongoing activities, witnessing of testing and inspection of work. This group _also reviews procedures, safety-related (Q) test packages and work orders, and verifies non-Q work orders are indeed correctly classified prior to initiation of actual work (except during backshifts). There is continuous onsite QC presence during the six day work week. The Start-up schedule is reviewed to assess manpower needs and the transfer of other QA per-sonnel into this unit is ongoing.
The monitoring of station personnel work activities is assigned to a QA operations group consisting of a supervisor and two engineers.
This group will be augmented when activities increase.
Currently, station procedures are being reviewed and surveillances conducted on the contractor performing the ISI Baseline examination.
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.The Nuclear QA ~ organization is responsible for auditing Nuclear Department activities that include work by plant personnel.
The group responsible for such audits has developed an audit schedule for 1985-86.
A -general type of audit has been conducted that addressed several functional areas. One area excempted during this audit was preventive maintenance and is to be audited in July. The audit' supervisor acknowledged the above-finding.
It was determined that QA/QC personnel met or exceeded established requirements for their positions based on the following.
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observation of duty performance during accompaniments
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discussions and interviews with personnel review of training, experience and education records
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No violations were identified.
6.0 Unresolved Items Unresolved Items are matters about which more information is required in order to ascertain whether they are acceptable items or Violations.
An unresolved item identified during this inspection is discussed in paragraph 3.
7.0 Management Meetings Licensee management was informed of the scope and purpose of the inspec-tion at the entrance interview on April 8,1985. The findings of the in-spection were discussed with licensee representatives during the course of the inspection and presented at the April 12, 1985, exit interview (see paragraph I for attendees).
At no time during the inspection was written material provided to the licensee by the inspectors.
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