IR 05000369/1989025
| ML19351A303 | |
| Person / Time | |
|---|---|
| Site: | McGuire, Mcguire  |
| Issue date: | 09/25/1989 |
| From: | Belisle G, Lenahan J, Szczepaniec A NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML19351A302 | List: |
| References | |
| 50-369-89-25, 50-370-89-25, GL-89-10, IEB-85-003, IEB-85-3, NUDOCS 8910190270 | |
| Download: ML19351A303 (10) | |
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NUCLEAR REGULATORY COMMIS$10N
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Report Nos.: 50-369/89-25 and 50-370/89-25 Licensee: Duke Power Company 422 South Church Street Charlotte, NC 28242
Docket Nos.:
50-369 and 50-370 License Nos.:
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Facility Name: McGuire 1 and 2 l
Inspection Conducted:
August 14-18, 1989
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Inspector:
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J. Lenaha t '
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Dat'e Sfgne'd
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A. J. Szczepaif,1fU ~ '
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Date Signed
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Approved by:
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G. A. Belisle,' Chief Dite 51gn'ed Test Programs Section
Engineering Branch Division of Reactor Safety
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SUMMARY Scope:
i This routine unannounced inspection was conducted in the areas of Inspection and Enforcement (IE)Bulletin 85-03, Motor Operated Valve Common Mode Failure i
During Plant Transient Due to Improper Switch Settings, and followup of licensee actions on previous inspection findings.
Results:
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In the areas inspected, violations or deviations were not identified.
The licensee's actions required by IE Bulletin 85-03 were satisfactory.
- Appropriate testing was either completed or in process of completiun.
No particular strengths or weaknesses were observed.
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REPORT DETAILS
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Persons Contacted
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Licensee Employees
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- J. Day,. Associate Engineer, Compliance K. Kelly, Maintenance Engineer T.'McConnell, Plant Manager J. Oswald, Nuclear Production Engineer, Performance
- M.. Sample, Maintenance Superintendent
- R. Sharpe, Compliance Manager D. Smith, Performance Engineer
- R. Travis Operations Superintendent
- R. Turner, Senior Technical Specialist, Maintenance Other licensee employees contacted during this inspection included engineers and mechanics.
NRC Resident inspectors
- T. Cooper, Resident Inspector
- K, VanDoorn, Senior Resident Inspector
- Attended exit interview 2.
IE Bulletin 85-03 Followup (25573)
(Closed) 369, 370/85-BU-03, Motor Operated Valve Common Mode Failure During Plant Transients Due to Improper Switch Settings The purpose of this bulletin was to require licensees to develop and implement a program to ensure that switch settings for High Pressure Coolant Injection and Emergency Feedwater System Motor Operated Valves (MOVs), subject to testing for operational readiness in accordance with 10 CFR 50.55a(g), are properly set, selected, and maintained. Action Item (a) required a review of the design basis for the operation of each valve; Item (b) required that correct switch settings be established; Item (c) required differential pressure testing or alternate methods to demonstrate operability with the settings from Item (b); and Item (d)
required plant procedures to be provided to assure maintenance of correct switch settings throughout plant life. Actionitems(e)and(f)specified reporting requirements for IEB 85-03 action items.
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A supplement to the bulletin was subsequently issued to expand the scope to include all safet The bulletin was then supersedeo by Generic Letter (GL) y-related valves.89-10, Safety-Related Motor-Operated Valve
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Surveillance, dated June 28, 1980, which further extended the scope of the
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program - to include safety-related MOVS as well as all position -
L changeable MOVs as defined in the generic letter.
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The ; inspector held discussion with appropriate licensee personnel and L
reviewed the following:
L Duke Power letter dated May 15, 1986, stating the initial response to Action Item (a) and the plan and timing for completion of Action
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l-Items,(b) through (d), as requi/ed by Action Item (e).
K Duke Power letter dated March I,1989, providing the report on
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completion of the program stated in the May 16, 1986, letter as
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requiredbyactionitem(f).
McGuire Nuclear Station EMO Valve Torque / Limit Switch List Selected procedures listed in the Duke Power March 7,1989, letter, f-a.
IE.Bulletin 85-03 Program Overview Forty-three MOVs per unit (86 total) are in the original IE Bulletin
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85-03 program..The bulletin valves are gate (42) and globe (1)
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valves with Rotork or Limitorque actuators. All are AC driven. The valves were tested using both Motor Operated Valve Analysis and Test System (M0 VATS) and Valve Operttor Testing Evaluation System (VOTES)
diagnostic testing equipment.
The testing was completed by plant personnel certified in use of the test equipment.
The licensee
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expanded the program to include all safety-related valves prior to f
the bulletin supplement issuance, but the testing is on-going and was not included in the licensee's final response.
Testing for the original bulletin valves was not performed at the maximum differential pressure; however, the licensee has initiated a test plan to validate the calculational methodology used to establish torque switch settings.
In the March 1,1989, final response to IE Bulletin 85-03, the licensee committed to provide additional information concerning the test methodology and validation.
This information will be provided in response to GL 89-10.
Several operability questions were generated as a result of the design basi evicw and the establishment of torque switch settings.
These were. teviously documented, and resolved, by Licensee Event Reports 369/86-20 Unit Shutdown Due to Incorrect Torque Switch Settings on Rotork Motor Operators, and 369/86-09, Motor Operated
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Valves Found with Undersized Operators Due to Design and Perscnnel
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Errors.
Signature analysis testing identified 15 of the 86 MOVs tested as having low "as found" closed torque switch setpoints. All bulletin MOVs with Rotork actuators were subsequently found to be in good condition.
Six Limitorque actuators were refurbished due to
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mixed grease concerns and a defective torque switch was replaced on one Limitorque actuator.
t The testing results summary also indicated that four valves, 2CA38,
50, 54, and 2NIO9, had been lef t with thrust values below those i
reouired.
The licensee stated that the CA system valves had an y
incorrect required thrust value listed in the sumary and that the
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fourth valve had an inac. curate "as-left" value listed due to i
inconsistent zeroing of test equipnent.
The paperwork and test data for the appropriate valves was reviewed and found to be satisfactory.
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The licensee stated that they would take the necessary action to t
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correct inaccuracies in the data summary.
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Current Status of IE Bulletin 85-03 Action Iteas (a) through (f).
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(1)
Item (a) required that the design basis for each bulletin valve operator be reviewed and documented.
This item was completed.
Review of the licensee's initial response and additional information provided by subsequent letters indicated that applicable safety-related valve selection, valve maximum differential pressure, and the program to assure valve operability were acceptable.
The design basis conditions were calculated and documented in licensee design documents.
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appears, however, that no specific value was incorporated to
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account for test equipment inaccuracies.
A positive 15 percent tolerance was allowed in the switch settings to recog.12e miscellaneous inaccuracies.
The licensee stated that test equipment accuracies will specifically be addressed in the future
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and current torque switch settings will be evaluated to determine if they have been affected.
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(2)
Item (b) required that correct switch settings be established and the methods for selecting switch settings be reviewed and revised as necessary.
The licensee also comitted to reviewing overload switch sizes and verifying Electro-hotor Operated (EMO)
setpoint listings.
The review of the program indicated this had been satisfactorily accomplished, even though, as stated earlier, four changes to valve setpoints had not been
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incorporated into the setpoint listing Generally; however, the EMO setpoint listing was initially modified for each bulletin valve stating the required thrust valves for closing at maximum differential pressure.
Overload switch sizing was not required
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to be adjusted since overload switches are not used to operate the actuators, but are used only for alarm and indications.
Required thrust values and appropriate switch settings are
I contir.uing to be calculated for the non-bulletin safety-related l
valves.
Inservice testing, including timing and limit position, is performed following torque switch setting.
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The logic for the bulletin valve operation is as follows:
During the close to open cycle, the actuator notors are
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deenergized by ectivation of the open limit switch with the open torque switch acting as a backup. The open torque switch bypass switch is set at 50% i 25% of the stem travel; this allows a r
liberal but acceptable setting range and also alleviates torque switch balancing problems.
Actuator motors are deenergized during the open-to-close cycle by actuating the closed torque
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switch.
(3)
Item (c) required that switch settings be changed as appropriate
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and each valve be demonstrated operable.
As indicated by the final response, testing was successfully completed; however, testing was not performed at maximum differential pressure,
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Justification for the nethodology used is provided in the b-licensee's March 1,1989 response.
The final response will be
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evaluated as described in subparagraph (6), below.
(4)
Item (d) required that procedures be prepared or reviewed to
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ensure switch settings are maintained throughout the life of the
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plant, that applicable industry standards be considered, and that procedures include provisions to monitor valve performance.
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A review of the program indicates this requirement was met, i
(5) The licensee's response to the bulletin, requested by Action Item (e), as stated earlier, was found acceptable.
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(6) The review of the final response required by Action Item (f)
will be addressed in future inspections, either separately or as
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part of the GL response review.
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Generic Letter 89-10 states responses to IE Bulletin 85-03 are no longer required; however, many of the requirements of the bulletin are now part of the generic letter requirements.
Any additional
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responses committed to by the licensee, such as intent to perform
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zero differential pressure testing with validation for such testing, will be addressed in the response to the Generic Letter.
IE Bulletin 85-03 is therefore closed.
Future inspections will be conducted in
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accordance with GL 89-10.
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Temporary Instructions (TI) Closeout (Closed) Temporary Instruction (TI) 2515/73 - Inspection Requirements for IE Bulletin 85-03. This TI was issued to define the inspection, reporting
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and evaluation responsibilities of NRC inspectors for IE Bulletin 85-03.
The inspector completed the inspector requirements detailed in the Tl during this inspection (see paragraph 2).
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Licensee Identified Item i
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(0 pen)LER 369/88-012:
Investigation of Possible Valve Actuator Problems, d
On February 3, 1988, licensee and NRC personnel, while inspecting valves
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during an equipment qualification review, discovered that the motor had
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fallen off the actuator on Unit 2 RHR pump valve 2ND-2A. The licensee
determined that the motor had driven itself off past the mounting screws
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when subjected to stall torque.
Further investigation of this problem l
disclosed that the original actuator motor on this valve had been replaced with a new motor in 1985 and that the same screws from the old motor had
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been used to mount the new motor on the actuator.
Examination of the old and new motors disclosed that the diameter of the holes in the new motor
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flange were larger than the holes in the old motor flange.
Using the
smaller screws from the old motors was sufficient to hold the motor during
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normal operations, but the motor was able to pull itself free under stall
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condition.
The licensee determined that the old motors were those purchased prior to 1978, while the new motors, with the larger holes, were those purMsed sut, sequent to 1978.
The licensee's r.orrective actions were initially directed toward the Rotork size 90 NAI motors since a known failure had been identified at Catawba concerning this size motor.
Two safety-related actuators were identified which had new size 90 NAI spare motors installed. The actuators were inspected and found to have the proper size screws mounting the motors.
Actuators with new size 30 NAI motors were examined on March 1, 1988.
One was identified with incorrectly sized mounting screws.
The proper size screws and washers were installed on this motor on March 8,1988.
Additional corrective actions included revision of the Rotork Manual, MCM 1205.00-570, Rotork Instructions and Maintenance Manual, t,nd procedure IP/0/A/3066/02B, Rotork Actuator Troubleshooting and Repair.
The inspector examined the current copies of the manual and procedure and verified that they had been revised to included instructions for mounting pre-78 (old) and post-78 (new) motors, and that differences in bolt-sizes, lockwashers, and torque requirements were addressed in the procedure.
l Additional corrective action remaining to be completed to close this LER
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l is identification, inspection, and modification, if necessary, of mounting i
screws on Rotork size 7/11 NAl motors installed on safety-related l
actuators.
The inspections of affected Unit 2 actuators are underway l
during the current Unit 2 refueling outage and will be completed for Unit I actuators during the next Unit I refueling outage.
LER 369/88-012 will remain open pending NRC revicw of the licensee's completed cortective actions.
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Action on Previous Inspector Finding (92701 and 92702)
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(Closed) Inspector Followup Item (IFI) 369, 370/86-33-01:
Followup
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on Final Resolution to Rotork Torque Switch Issue
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Rotork torque switches have been verified correct for all valves covered by IE Bulletin 85-03.
The licensee's IE Bulletin 85-03 c
program also included all other safety-related valves and i
verification of torque switch settings for these valves is currently
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underway.. Generic Letter 89-10 has superseded IE Bulletin 85-03 and
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is now the document governing MOV operability verification.
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(0 pen)
IFI 369, 370/87-40-02:
PORY Corrections i
Changes which the licensee made in the packing of Pressure Operated t
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' Relief Valves (PORVs) resulted in increased stem friction during
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valve position changes.
The closure force for these valve is i
provided by valve sprir.gs, air pressure, and flov, through the valves.
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$1nce the air pressure was provided by a non-seismic air system, the j
licensee implemented a design modification to provided a seismically
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designed nitrogen supply system to the Unit I valves.
The inspector examined Nuclear Station Modifi':ation NSM-MG-1-2102, Redesign of
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Instrument Air Supply Tubing - Provide Seismic Supported Supply Line
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for PORV-Pressurizer.
The inspector examined Variation Notices SN
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MPVN-0852, 0853, and 0863 and Work Requests 95709, 95988, 95989,
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95990, and 96198 and determined that the installation of seismically
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mounted air (nitrogen) supply line to ;he Unit 1 PORVs was completed.
The design for the seismically mounted air supply line for the Unit 2 r
PORVs is in progress.
The licensee is also in process of completing a design study to determine how valve par. king changet reduce friction, and if flow forces, in addition to spring force, would be sufficient to assure closure of the PORVs.
The design study will be
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completed by October 1, 1989. Unresolved Item 369, 370/87-40-02 will
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remain open pending NRC review of the licensee's completed design study. and completion of any corrective actions, c.
(Closed) Unresolved Item 369, 370/88-13-01:
IST Program Deficiencies An Office for Analysis and Evaluation of Operational Data (AE00)
diagnostic evaluation team determined that the licensee implemenced a relief request pertaining to testing of the Residual Heat Removal (RHR) outlet crossover block valves ND-15 and ND-30 prior to receiving formal NRC approval.
Review of the licensee's justification for the relief request disclosed that it was implemented in accordance with the recomendation of Information Notice IE 87-01, RHR Valve Misalignment Causes Degradation of ECCs in PWRs, and a Westinghouse Owners Group letter dated February 27, 1988.
j These documents recomended reviewing surveillance requirements to
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assure availability of injection to all four cold legs during operations and thus resulted in changing the performance test m
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surveillance frequency for vaives ND-15 and ND-30 from quarterly, per j
ASME Section XI, to cold shutdown.
The inspector examined a Duke
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Power letter dated May 6,1988, which contained the formal submittal of Revision 10, for Unit 1, and Revision 6. for Unit 2, Inservice i
Inspection Testing program to NRC.
The above changes were
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incorporated in these Submittals.
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(Closed)UnresolvedItem 369, 370/88-13-02:
Relief Yalve Testing
L The licensee is currently required to periodically test only the pressurizer and main steam safety relief valves.
These valves are tested per Technical Specification requirements.
The licensee is
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crmmitted tc the 1980 edition of IWV which does not require testing other relief valves.
After reviewing this issue, the licensee has taken the position that all safety-related relief valves should have
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some kind of periodic setpoint check.
The licensee is currently developing a list of all safety-related and nonsafety-related relief
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valves and will develop procedures to periodically test these valves as part of their preventive maintenance program.
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(Closed) Violation 369, 370/88-13-03:
Stroke Timing Deficiencies The licensee's corrective actions for this violation are stated in
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their July 8, 1988, response to NRC.
The licensee revised affected i
performance test procedures to delete use of the stopwatch as a
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source of data to meet ASME,Section XI, requirements when the computer is available for valve stroke timing.
The inspector examined procedure PT/0/A/4700/15G, Performanca Calfbrotion of
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Stopwatches, which the licensee has written and implemented to cover calibration of stopwatches used to determined valve stroke times when the computer is not available for use in the stroke timing test.
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(Closed)IFI 369, 370/88-31-09:
Followup of Licensee Verification of Limitorque MOV Torque Switch Settings
The inspector examined procedures IP/0/A/3066/02A, Installation, Removal and Setup Rotork Actuators, and IP/0/A/3190/10 Limitorque Operator Preventive Maintenance, and verified that the procedures had
been revised to include requirements for recording torque switch
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This requirement is included as step 10.2.8 on Enclosure 11.8 to IP/0/A/3066/02A, and as step 10.15.5 on Enclosure 11.2 to IP/0/A/3190/10.
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(Closed) IFI 369, 370/88-31-12:
Verify Correction of Cycle Time for Auxiliary Feedwai,er Valves The inspector examined procedures PT/1/A/4252/02P, CA Valve Stroke i
Timing-Quarterly, and PT/2/A/4252/02, CA Valve Stroke Timing-
Quarterly, and verified that the cycle times for Unit 1 and 2 valve l
numbers CA-38B, CA-508. CA-54AC and CA-66AC had been increased from
10 to 12 seconds.
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(Closed) IFI 369, 370/88-31-14:
Verify Procedure Changes to ImplementInitiationToLimitValveStrokeTimes(VSTs)
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The inspector examined selected performance test (PT) procedures for
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quarterly and shutdown valve stroke timing surveillances and verified
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that the procedures had been revised to require recording VSTs. The
L inspector determined that data sheets attached to varicus PT I
I procedures had been revised to include steps for recording VSTs, and
.for reviewing VSTs tn assure compliance with acceptance criteria.
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(Closed) IFI 369, 370/88-31-15: Verify VST Records Improvements
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f The inspector examined selected completed PT procedures implemented i
for valve stroke timing and the licensee's IWV data books and the IWV data base and determined that the licensee had improved their methods for recording and evaluating VST data.
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(Closed) IFI 369, 370/88-31-16:
Verify Procedure Changes, Re: 24 Hour Evaluation Period The inspector examined procedure PT/1/A/4252/01 and PT/2/A/4252/01, Auxiliary Feedwater Pump Performance Test, and verified that the procedures had been clarified by deleting the reference to a 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> evaluation period which may have been permitted prior to declaring the pumps inoperable, provided ti,e 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> evaluation period did not conflict with the Technical Specification requirements, k.
(Closed) IFI 369,370/88-31-17:
Verify Improvements in Engineering Evaluations of Failed IWV/lWP Equipment The inspector examined the licensee's Nocedure titled, " Failed
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Surseillar.ce Engineering Analysis," whien was written by the licensee i
to document the methodology used in their evaluation of IWV/lWP components which do not meet acceptance criteria during surveillance
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tests.
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(0 pen) Uniesolved Item 369, 370/88-31-18:
Include Certain Check Valves in the IW Program.
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.This item concerned the licensee not including testing check valves 1SA-5 and ISA-6 in the IWV surveillance testing program.
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licensee prepared Relief Request RR 6A-1 to document the justification for not testing these valver and to provide an
I alternative testing method.
The licensee initiated Problem
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Investigation Report (PIR) 0-M87-0301 to document and evaluate this problem and to determine if any additional valves should be included I
in the IWV program.
A design study is currently in progress to examine all safety related valves, ascertain which ones require IWV testing, and if applicable, determine specific test requirements, and acceptance criteria.
The licensee has committed to complete the i
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a design study by ' October 31, 1989.
Pending NRC review of the l
licensee's design study and resolution and close out of PIR-l 0-M87-0301, Unresolved item 369,370/88-31-18 will remain open, i
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(0 pen)IFI 369 370/88-31-19: Followup of Check Valve Design Study L
The check valve design study is being performed as part of the design
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L study to resolve PIR 0-M87-0301, discussed in paragraph 5.1, above.
This IF1 will remain open pending review of the above referenced
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L completed design study.
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'(Closed)IFI 369,370/88-31-20: Verify Testing of Relief Valves.
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This item is a duplicate of Unresolved Item 369, 370/88-13-02, which
1s discussed in paragraph 5 d. above.
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Exit Interview-i i
l The inspection scope and results were summarized on August 18, 1989, with those persons indicated in paragraph 1.
The inspectors described the
areas inspected and discussed in detail the inspection results.
Proprietary infointion is not contained in this report.
Dissenting
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comments were not received from the licensee.
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