IR 05000358/1979029
| ML19211D103 | |
| Person / Time | |
|---|---|
| Site: | Zimmer |
| Issue date: | 11/29/1979 |
| From: | Knop R, Naidu K, Vandel T NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML19211D101 | List: |
| References | |
| 50-358-79-29, NUDOCS 8001160367 | |
| Download: ML19211D103 (9) | |
Text
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U.S. NUCLEAR REGULATORY COMMISSION
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OFFICE OF INSPECTION AND ENFORCEMENT
REGION III
Report No. 50-358/79-29 Docket No. 50-358 License No. CPPR-88 Licensee: Cincinnati Gas and Electric Company 139 East 4th Street Cincinnati, OH 45201 Facility Name:
Wm. H. Zimmer Nuclear Power Plant Inspection At:
Zimmer Site, Moscow, OH Inspection Conducted: November 6-8, 1979 hl u
cr Inspectors:
T. E. Vandel
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Approved By:
R. C.
Projects Section 1 Inspection Summary Inspection on November 6-8, 1979 (Report No. 50-358/79-29)
Areas Inspected: Review of corrective action taken on previously identified items of noncompliance and unresolved items; IE Bulletins, 50.55(e) reports; evaluating implementing procedures for fire shields and penetration fire shMlds; ASME certification status. The inspection involved a total of 44 inspector-hours on site by two inspectors.
Results: No items of noncompliance were identified.
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DETAILS Persons Contacted Cincinnati Gas and Electric Company (CGE)
- B. K. Culver, Project Manager
- R. P. Ehas, QA&S Engineer J. F. Weissenberg, QA&S Engineer
- W. W. Schwiers, Principal QA&S Engineer R. L. Wood, QA&S Engineer Kaiser Engineers, Inc. (KEI)
- K. Baumgarten, Acting QA Manager R. Marshall, Project Manager Tech-Sil Inc. (Tech-Sil)
T. Hansen, QA Manager
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R. Petersmann, QC Inspector M. Troman, Technical Advisor Kramig Company Incorporated G. Grosardt, Superintendent
- Denotes those present at the exit interview.
Other CC&E and HJK personnel were ccntacted during the course of the inspection.
Licensee Action on Previous Inspection Findings (Open) Noncompliance (358/79-13-01): Additional information on the relation-ship of EPDM Compound and 'E' style diaphram. The licensee considerr. Goodyear's certification inadequate and plans to replace the flexible connections with those with adequate certifications.
(0 pen) Unresolved Item (358/79-14-01):
Preparation of checklists to verify the adequacy of HVAC equipment installation. The leiensee requested S&L, the A. E. to provide instructions to prepare the checklists.
(0 pen) Noncompliance (358/79-28-01): Housekeeping conditions adverse to quality in the floor above the switchgear room adjacent to the control room.
The inspector verified the corrective action taken as outlined in CGE letter dated October 19, 1979. Revisit to the area indicates considerable improve-ments; the opening into the control room has been closed.
S&L has been requested to rereview the design and eliminate the zonolite floor. The QA
.
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electrical engineer requested the CGE project manager in a letter dated a
November 8, 1979 to restore cleanliness of the electrical and electronic instruments on the control panel which may have been af fected.
Relative to performing welding activities without adequately protecting installed equipment, the inspector reviewed letters dated October 16, 1979 from the HVAC contractor and KEI project manager directing the respective craft personnel to exercise care to protect the integrity of installed equip-ment. The inspector observed welding activities in progress in the control room and determined that the installed cables and equipment in the vicinity were adequately protected.
This item consists of two parts, namely cleanliness of the zonolite floor and adequate protection during welding activities; the former part remains open and the latter part is considered closed.
(0 pen) Noncompliance Item (358/79-12-01): Welding proceeding without completion of inspection hold points. The licensee committed, in their letter of response dated July 10, 1979, to conduct a review of all records relative to the pipe whip restraints.
It was the inspector's understanding that this review is currently in progress. This item will be reviewed during a future inspection.
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(Closed) Noncompliance Item (358/79-14-07): The frequency of management auditing was neither scheduled nor performed in accordance with the FSAR commitment. Even though the planned QA Manual revision, to require biyearly management audits as committed in the FSAR instead of the yearly, is uncompleted, the current auditing schedule reflects such audits scheduled for January and July of 1980.
In addition, an audit was performed in July 3' -31, 1979.
The audit report, number 0430-008-014 was issued on October 5, 1979. The inspector concluded that this item is resolved.
(0 pen) Noncompliance Item (358/79-14-08): Old audit report findings had neither been followed up nor closed out.
Further review of U.S. Testing management audits showed that old findings (in 1976 and 1977 audit reports)
were not closed out.
The 1978 management audit report carried four findings as open from previous reports, however, the 1979 failed to mention or deal with these old items (one 1976 report item and three 1977 report items).
Further, it was found that the licensee response to the 1978 management audit failed to respond adequately. The corrective action to complete this item will be reviewed in the future.
(Closed) Noncompliance Item (358/79-14-09): Untimely responses to field audit reports.
The licensee committed actions of providing a response due column to field audit 109 sheets and weekly review of the due dates noted will be performed. This corrective action has been done and all identified late responses have been corrected. This matter is considered resolved.
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(Closed) Noncompliance Item (358/79-14-10):
Audit items not properly
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classified or documented.
Licensee actions reviewed and corrected documen-tations for audits nos. 166 through 256.
In addition, audits 217 and 223 have been correctly classified. AS&S Procedure 18-QAS-03 was revised to require identifications of items as deficiency, observation or suggestion.
This item is closed.
(Closed) Noncomplm.. ice Item (358/79-14-11): Annual audits were not performed for Kaiser QA procedures ne. 4 and no. 7.
The annual audit was performed for the QAP-4 as committed to in the licensee letter of response with audit report no. 273 as issued.
It appears that the audit of QAP-7 did not meet the dead-line of August 31, 1979 however, the report is anticipated to be issued in the near future.
It was additionally learned that scheduling for audits through July 1980 include auditing of those QAP's.
This item is closed.
(Closed) Noncompliance Items (358/79-14-12 and-13): Failure to audit Element 11 (QAP-10 Special Processes), as well as SPPM-3 (welding) and SPPM-4 (nondestructive examination) as listed on page 14 of report details and also Element 16 (QAP-16 control of noncomforming material, parts and components) as listed in last paragraph of page 16 of report details (unnumbered). An audit performed July 1, 1979 included audit of the above referenced concerns. Routine audits no. 383 done on July 17, 1979 and no. 379 done on August 1, 1979 also covered the Elements 11 and 16.
The findings of both have been closed out.
The future audit schedule includes routine coverage of these items.
Corrective action included adding an auditor for routine auditing coverage in the future. This item is closed.
(Closed) Noncompliance Item (358/79-14-18): Recurring discrepancies were not analyzed. HJK audit report no. 407 dated August 14, 1979, was conducted to review essential NR's for recurring discrepancies. The analysis has been completed and approved without additional concerns being generated.
It was additionally learned that the corrective action included a periodic review (every six months) which would be scheduled with the next audit to be performed in February, 1980. This item is resolved.
Other Inspection Areas 10 CFR 50 Section 50.55(e) Reportable Deficiencies (Closed) Over pressurization of the steam jet air ejector heat exchanger (tube side). NR number 7247R1, dated February 21, 1979, stated that over pressure to 1200 psi of the LPCS piping system occured in addition to others.
The A-E (Sargent and Lundy) analyzed the piping system and valves with dispositions as follows:
1.
Carbon steel piping 3/4" up to 12" acceptable since stress was well below yield point.
2.
The one stainless steel 3/4" pipe is likewise o.k.
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3.
Six hundred pound valves are acceptable with the pressure experienced
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only being a repeat hydro test.
4.
Three hundred pound and 150 pound valves the manufacturer should be consulted.
5.
The relief valve causing the problem should be retested and reset.
Further information available (Construction Engineering Report dated April 14, 1979) stated that the valve manufacturers recommended a seat leakage test be conducted on the valves and that this test was performed without any leaks being detected and it further stated that the relief valve had been removed, tested and reset of set points done. The NR was signed as completed on October 25, 1979. The inspector indicated that he had no further questions regarding this item.
10 CFR Part 21 Reportab'e Items l
Tube Turns 45 of Wrong Material The inspector determined that the four 45 ells affected by this report had been removed as follows.
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1.
One Ell was replaced in line #1WR14A4.
2.
Three Ells were shipped off site by shipping order 4692.
This completes this item.
Licensee Action on IE Bulletins The RIII inspector verified the licensee's replies to the following NRC Bulletins and Circulars by observing the various electrical panels and other installations.
1.
Bulletin 75-03 Incorrect lower disc spring and clearance dimensions in ASCo solenoid air pilot valves series 8300 and 8302. The licensee, in a letter dated April 30, 1975, stated that these types of solenoids are not used. The inspector did not observe these types of solenoids in the installations.
2.
Bulletin 75-06 Potential defects in Westinghouse contro switches type OT-2.
This type of switch has not been used.
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3.
Potential relay coil failures in General Electric type relays HFA, HGA, HKA, or HMA. The licensee reply dated April 2, 1976 states that the purchase order for Zimmer was placed after 1969, subsequent to the change over to Lexam coil bobbins; as such they do not anticipate any re'ays with the older white nylon spool. The inspector observed that 12.
DC HFA type relays are used as Scram Auxiliary Relay in the Reactor Protection System. A " translucent dise" with a black f'.nish on the outer periphrey. A GE letter dated May 10, 1976 indicates that the modification on the spools was completed prior to 196R.
4.
Bulletin 76-03 CGE attempted to use the repair kit to fix the General Electric STD type differential relays. However, due to problems in maintaining the set points, CoE replaced the STD type relays with BDD type differ-ential relays. The inspector observed BDD type relays installed on the main and auxiliary transformer panels.
5.
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Delay set point drift on ITE Imperial time delay relays (catalog No.
J20T31P20 and J20T3P30).
The inspector observed that these relays are not used in the Diesel Generator start up systems.
6.
Bulletin 77-02 Potential for failure in the latch mechanism of certain Westinghouse AR type relays.
AR type relays are not used in this plant.
7.
Bulletin 78-05 Potential for malfunction GE relay type CR105X.
CGE letter dated June 8, 1978 states that these relays are used in the Reactor Pro-tection System for the following purposes:
a.
Annunciation and Indication b.
Signals to the Process Computer c.
Spare Contacts d.
Backup scram solenoids CGE contends that the first three are not safety related and that the fourth is not safety related because the backup function is not required by any regulation or standard and no credit is taken for the function in the FSAh.
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During discussions with the licensee, the inspector determined that
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CGE electrical construction engineer disagrees with the safety classi-fication of the scram backup protection. As a result, GE initiated Field Deviation Dispostion Request (FDDR) #KN-1-819 dated September 27, 1979 to replace eight suspected defective CR105D112 scram contactors, four each in panels H-13-P611 and H-13609 with contactors type #145C3209P003.
8.
Bulletin 78-06 Potential for defective coils in Cutler-Hammer "M" type relays. There are no Cutler-Hammer "M" type relays used.
9.
Bulletin 79-09 Potential for failures in General Electric AK-Z type circuit breakers.
AK-2 circuit breakers are not utilized.
10. Circular 76-04 Neutron monitor and flow bypass switch malfunctions.
The licensee's reply was-based on GE's letter CGE-693 dated November 4, 1976 which states that GE switch type CR2940 are not used or planned to be used on Zimmer. Switches manufactured by Square D are used.
11.
Bulletin 78-12, -12A, -12B Atypical Weld Material in RPV Welds. A General Electric Company (GE)
with attached:
(1) CBIN certificate letter and report to NRC IE Headquarters dated April 24, 1979, and (2) GE confirming letter of concurrence was submitted to NRC RIII on May 25, 1979 in a timely fashion.
It was understood that NRC IE HQtrs were to perform a veri-fication audit later.
12.
Bulletin 79-15 Deep Draft Pumps. The inspector conducted a review regarding the LPCS, HPCS and RHR pumps discussed. All pumps were manufactured by Ingersoll Rand for Zimmer. The inspector determined the following.
No planned actions were involved beyond disassembly, inspection a.
and reassembly of all the pumps.
b.
The noted disassembly, inspections and reassembly has been done as stated in the licensee response dated August 31, 1979.
c.
No deficiencies were identified.
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The inspector was unable to see any long term operation test results,
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however, a test document was located at S&L regarding a 13 hour1.50463e-4 days <br />0.00361 hours <br />2.149471e-5 weeks <br />4.9465e-6 months <br /> 15 minute prototype operation test. This matter remains unresolved until the test document can be reviewed by the inspector.
(50-358/79-29-01)
Functional or Program Areas Inspected 1.
Review of Fire Shields and Fire Seals Work Activities Activities related to fire shields and fire seals are being performed by Tech-Sil, a subcontractor to Kramig Company, the insulation contractor.
Tech-Sil prepared specifications #NP-5-LSE and #NP-5-SE for installing leaded silicone elastomer and RTV silicone clastomer respectively. The sealing of electrical penetrations will commence after the electrical design drawings are approved.
The inspector observed activities in progress to seal mechanical pene-trations #2176 at floor elevation 473' 5" in the turbine building as indicated in drawing M-531 sheet 5, discussed the implementation of procedures with Tech-Sil personnel and determined the following:
a.
Two liquid elastomers were emptied into a mixer and thoroughly mixed. A QC inspector was present during the mixing operation.
b.
The machine was rolled to the turbine building and the mixer was activated again for a specific time. The QC inspector collected in a dixie cup, weighed the sample, computed the density and determined that the density was within the acceptable limits. The QC inspector released the pouring of the compound in the penetration.
The QC inspector was observed to document the inspections.
c.
d.
Review of receiving report (Form TS-QA-3) dated October 9, 1979 indicates that Tech-Sil Procedure QC-203, titled, " Quality Control Procedure for On Site Material Receiving" was being adequately implemented. The receiving report indicates that several 910 lb. containers of TS-MS0060 leaded elastomer and 30 lb. containers of TS-MS-009 cure accelerator were received.
Individual lot numbers with expiring dates were indicates for the containers. No special storage requirements are required to preserve the material.
e.
Identification and control number on the container is retained until used; prior to mixing the chemical, the identification is transferred on to a system log (Form TS-QA-Sa).
f.
Nonconforming material consists of leaking containers. A reject tag is applied to the container and the container is returned to to the manufacturer.
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g.
(1) A typical system of - (Form RS-QA-52) indicates the (serial)
system #, the lot numbers of the elastomer and accelerator and their respective weights.
(2) A test log (Form TS-QA-Sb) indicates the serial number of the density test performed (twice a day), the system #
(cross references with those serial numbers provided in Form TS-QA-Sa), the date the tat was performed, the iden-tification of the scale, the time tested, pounds per cubic foot (pcf) and the computed density - 147' pcf minimum leaded elastomer and 70-95 pcf for unleaded elastomer.
h.
No elaborate repair procedure is necessary.
i.
No minimum curing time is required.
j.
No temperature restrictions for pouring the seal. Note:
for process pipe with service temperature greater than 392 F, the pipe has to be insulated prior to applying tire seal.
No items of noncompliance were identified in the above area.
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2.
ASME Certification System Requirements The inspector reviewed ASME certifications held by the licensee and by the contractor HJK and determined the status as follows:
An N Stamp Certificate of Authorization #N-610, expiring on a.
September 30, 1981, is held by the licensee Cincinnati Gas and Electxic Company.
b.
The constructor HJK holds an NA Stamp Number N-1436 expiring on June 25, 1982 and an NPT stamp Number N-1437 also expiring on June 25, 1982.
The inspector concluded that the ASME certifications are current and in order and he had no further questions.
Unresolved Items Unresolved items are matters about which more information is required in order to ascertain whether they are acceptable items, items of noncompli-ance, or deviations. An unresolved item disclosed during the inspection is discussed in the Licensee Action on IE Bulletins section of this report.
Exit Interview The inspectors met with licensee representatives (denoted in the Persons Contacted paragraph) at the conclusion of the inspection on November 8,1979.
The inspectors summarized the scope and findings of the inspection. The licensee acknowledged the findings as reported.
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