IR 05000410/1985036
| ML17055B087 | |
| Person / Time | |
|---|---|
| Site: | Nine Mile Point  |
| Issue date: | 01/08/1986 |
| From: | Linville J, Stair J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML17055B083 | List: |
| References | |
| 50-410-85-36, IEB-75-01, IEB-75-1, IEB-76-06, IEB-76-6, IEB-83-06, IEB-83-6, IEB-86-6, NUDOCS 8601210140 | |
| Download: ML17055B087 (20) | |
Text
U.S.
NUCLEAR REGULATORY COMMISSION
REGION I
Report No.
85-36 Docket No.
50-410 License No.
CPPR-112 Priority Category A/B Licensee:
Nia ara Mohawk Power Cor oration 300 Erie Boulevard S racuse New York 12302 Facility Name:
Nine Mile Point Unit 2 Inspection At: Scriba New York Inspection Conducted:
October
1985 to November
1985 Inspectors; R.A.
Gramm, Senior Resident Inspector L.T. Doerflein, Project Engineer S.D.
Hudson, Senior Resident Inspector Reviewed by:
Approved by:
J.R.
talr, eact r gineer J.
Linville, Ch'
Reactor r jects Section
,
DRP Date
/
Date Ins ection Summar
Ins ection on October 21 to November
1985 Re ort No.
50-410/85-36 Areas Ins ected:
Routine inspection by the resident and regional inspectors of work activities, procedures and records relative to Allegations, guality Per-formance Management Program, preoperational test conduct, preliminary testing, electrical equipment, Operational Preparedness Plan and Reactor Core Isolation C'ooling system walkdown.
The inspector also reviewed licensee action on pre-viously identified items and performed plant inspection tours.
The inspection involved 110 hours0.00127 days <br />0.0306 hours <br />1.818783e-4 weeks <br />4.1855e-5 months <br /> by the inspectors.
Results:
One violation was identified:
Improper bolting hardware installed within the Remote Shutdown Panels (paragraph 9).
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DETAILS 1.
Project Or anizations Nia ara Mohawk Power Cor oration NMPC Stone and Webster En ineerin Cor oration SWEC General Electric Com an GE ITT-Grinnel1 Industrial Pi in Inc.
ITT Johnson Controls Inc.
JCI Reactor Controls Inc.
RCI 2.
Plant Ins ection Tours
'The inspector observed work activities in-progress, completed work and plant status in several areas during general inspection tours.
Work was examined for any obvious defects or noncompliance with regulatory require-ments or license conditions.
Particular note was taken of the presence of quality control inspectors and quality control evidence such as inspection records, material identification, nonconforming material identification, housekeeping and equipment preservation.
The inspector interviewed craft supervision personnel, and quality inspection personnel in the work areas.
Observations are noted below:
The inspector identified a damaged instrument tube in the Reactor Build-ing.
SWEC issued Inspection Report ISA90109 to document the damage to tube R125.
The inspector was informed that non-safety related switchgear 16-2 had exploded and caused injury to several craftsmen.
The accident has been investigated by OSHA.
The inspector was informed that all switchgear were subsequently de-energized and cleaned out.
SWEC has reviewed the electri-cal design, and a design change is forthcoming..
No violations were identified.
3.
Licensee Action on Previousl Identified Items a.
(Closed)
VIOLATION (82-14-02):
Inspection of high strength bolt structural steel connections.
The licensee directed that a torque re-verification be performed for 200 connections installed by each the three contractors that had assembled structural steel.
The results for the applicable contractors were as follows:
L.K. Comstock: all 200 bolts were satisfactor N
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Higgins:
12 bolts of 202 inspected did not obtain the required torque.
SWEC engineering reviewed the connections and found the as-installed conditions were not detrimental to the connection designs The snug tight bolts were re-torqued and a bolt with stripped threads was replaced in accordance with Nonconformance and Disposition (N&D)Report 5008.
Cives:
68 bolts of 214 inspected did not obtain the required torque.
The bolts that were snug tight were re-torqued in ac-cordance with N8D report 5008.
The snug tight bolt conditions were evaluated by engineering and the connections were found within allowable stress limits.
On the basis of the initial results, SWEC directed that all friction connections with oversized or slotted holes inside primary contain-ment be reinspected.
The reinspection involved 423 connections and 2,820 bolts.
Seventeen (17) bolts were found with no torque and 126 bolts were undertorqued.
All bolts were retightened to the appropri-ate torque.
SWEC engineering concluded that the identified bolt problems would not have affected the integrity of the connections.
NKDs 7636 and 11,069 were generated to document and disposition the bolting deficiencies identified within primary containment.
QA In-spection Plan (QAIP) N2HSBOLTFA001 was revised to perform survei 1-lance inspection of different work crews on a weekly basis.
This item is closed based upon the extensive licensee reverifications to ensure that critical high strength bolt installations have been prop-erly torqued.
b.
(Closed)
CONSTRUCTION DEfICIENCY (83-00-09):
Nonconforming material supplied by Tube-line.
The inspector reviewed ITT letter ITT-LTR-6872 that described the following measures taken to identify field installed Tube-line material:
Fabrication isometrics associated with QA Category 1 safety re-lated piping were identified.
All pertinent Requisitions on Stores that were on file at either QC Documentation or QC Receiving were reviewed to identify Tube-line material that had been used for the QA Category
isometrics.
ITT issued Deficiency Report 6362 to document that three (3) fittings had been installed in safety related systems.
SWEC Nonconformance and Disposition (NKD) report 8544 documented the removal of the
inch flange installed in isometric 26-2.
The inspector reviewed Re-turned Material Reports 84-0040 and 83-1103 that documented the re-turn of the other two fittings to the supplier.
SWEC contacted site vendors to determine if other Tube-line material had been delivered to the site.
RECO industries identified thirty six (36) twelve inch caps and nine (9) elbows that had been received
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from Tube Line.
Nonconformance and Disposition (NED) report G142 documents the acceptability of the material based upon chemical anal-ysis and physical testing.
Further licensee investigation in response to NRC inquiries identi-fied twenty-six (26) additional Tube-line fittings as documented in NKD 13,118 and NMPC letter NMP2L-0520 to Region I.
The material was found acceptable based upon chemical analysis and physical testing.
The following additional corrective actions were instituted by the licensee:
SWEC QC receipt group was directed to place any Tube-line mate-rial on hold that is delivered to the si,te.
SWEC receiving QC and procurement QA re-reviewed all purchase orders associated with companies that potentially received Tube-line material.
No further Tube-line material was found onsite.
Other IE Bulletins ( IEB) were re-reviewed to assure that correc-tive actions implemented in response to the associated
CFR 50.55(e)
enveloped the entire problem scope described within the IEB.
This item is closed.
(Open)
CONSTRUCTION DEFICIENCY (84-00-39):
Improper conduct of weld radiography operations.
The inspector selected a sample of shop and field welds for the NRC Nondestructive Examination van inspection.
Licensee review of the weld sample and associated records identified a further case wherein a field weld had not been radiographed.
The adjacent weld had been radiographed twice in lieu of the required weld.
A single radiographer has been responsible for the three cases of duplicate radiography identified to date.
The licensee committed to perform a re-verification on all welds radiographed by the indi-vidual in questions This item remains open.
(Closed)
UNRESOLVED ITEM (84-06-06):
Level of Quality Control in-spection for non-safety related installations that are over Category 1 equipment.
NMPC issued Corrective Action Request (CAR) 84.0017 to document the lack of QC Verification for non-safety related seismic installations.
The following corrective actions were implemented:
SWEC Project Procedure (PP) 84, "Seismic Evaluation of Non-Nuclear Safety-Related Components (NNSRCs) in Nuclear Safety Related Areas" was revised to provide a minimum 10%
QC surveil-lance inspection of the NNSRCs.
The NNSRCs include piping, tub-ing, duct, conduit and cable tray supports, fire protection components, and mechanical equipment support, I (t V RCI reviewed the Quality Control (QC) program and found that all.
installations were treated as safety related.
ITT procedure FQC 4.2-14-17 was revised to require a
10% inspec-tion of Category II supports in safety related areas.
JCI procedure QAS-1105 was revised to require a
10% inspection of applicable instrumentation supports.
SWEC QCI 10. 11 was issued to provide instructions for performing the 10% inspection of NNSRCs.
The instruction provides guidance on transmitting the sample results to engineering for evaluation, The revised level of QC inspection will provide the requisite assur-ance that seismic non-safety related items will remain intact during Design Basis Events.
The inspector reviewed the FSAR sections 1.8 and 3.2 that describe the NMPC commitment to Regulatory Guide 1.29.
This item is closed based upon the level of QC inspection now re-quired for NNSRCs.
(Closed)
CONSTRUCTION DEFICIENCY (85-00-09):
ITT issued trim instal-lation details without SWEC approved design information.
ITT issued Corrective Action Request 666 to document the issuance of the trim drawings.
ITT issued a Stop Work Order 84-06 and recalled all plan-ner packages associated with trim installation, The inspector re-viewed the following documents that were issued,to resolve the issue:
Nonconformance and Disposition Reports:
IG-5034, IG-5035, IG-5036, IG-5037, IG-5038, IG-5039, IG-5077, IG-5940, IG-5941, IG-5942, IG-5943, IG-6541, IG-6542, IG-6572, IG-6573, IG-6592, IG-6620, IG-6621, IG-6622, IG-6650 and IG-6676.
Engineering and Design Coordination Reports C03057 and P12,348.
SWEC Calculation PX-77038.
SWEC engineering found the as installed Category 1 trim acceptable.
The piping installation requirements were amended to provide SWEC design information regarding proper trim installation.
ITT engineer-ing personnel were retrained regarding design control requirements.
This item is closed.
(Closed)
UNRESOLVED ITEM (85-19-05):
Minimum Spent Fuel Pool level.
The inspector reviewed various isometric drawings of the Spent Fuel Pool Cooling (SFPC)
System and performed a walkdown of the SFPC sys-tem return lines to the reactor cavity and cask storage areas to ver-ify that, considering the location of the line siphon breaker and
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check valve, a failure of any one of these lines would only decrease the Spent Fuel Pool level by approximately twelve feet.
The inspec-tor noted that such a failure would leave approximately ten feet of water above any stored spent fuel.
The inspector determined that this level complies with the position of Regulatory Guide 1. 13,
"Spent Fuel Storage Facility Design Basis,"
and the acceptance crite-ria of the Standard Review Plan.
(NUREG-0800), section 9. 1.3, "Spent Fuel Pool Cooling and Cleanup System."
The inspector had no further questions on this item.
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(Open)
UNRESOLVED ITEM (85-27-03):
Welding of pipe supports across embedment plant seams.
Nonconformance and Disposition Report 13578 was issued to document two further cases where the pipe support tube steel was welded across the seam.
The inspector was informed that the supports, BZ-450DJ and BZ-410MW, had been reworked to rectify the weld configuration.
The inspector reviewed informal SWEC engineering calculations of a finite element analysis that demonstrated the structural capacity of the original configuration.
This item remains open pending completion of the SWEC guality Control plant wide rein-spection of embedment plates and development of formal SWEC calcula-tions to show the adequacy of the supports identified above.
(Open)
FOLLOWUP ITEM (85-99-18):
Accuracy of FSAR information.
The inspector compared FSAR Figure 5.4-9 to diagram FSK 27-6E.
Valves F034 and F035 depicted in the FSAR were either deleted or moved on the flow diagram.
The inspector additionally reviewed Licensing Doc-ument Change Notice (LDCN) NMPC-352 that amended Sections 9. 1.4 and 7.7 of the FSAR regarding the fuel handling system.
The LDCN had been generated in part to respond to previously identified NRC con-cerns.
This item remains open.
4.
Licensee Action on IE Bulletins and Circular's The inspector reviewed licensee records related to the IE Bulletins and Circulars identified below to verify that: the IE Bulletins and Circulars were received and reviewed for applicability; a written response was pro-vided if required; and the corrective action taken was adequate.
Based on this review, the inspector closed the following IE Bulletins and Circulars for the reasons indicated.
IE BULLETIN 75-01, Through-wall cracks in core spray piping at Dresden-2.
The core spray piping is classified as ASME piping and will receive both hydrotest and pre-service examination prior to plant operation.
The in-spector reviewed FSAR sections 4.5, 5.2.3.4. 1, 5.3. 1, and 6. 1 and noted the following:
All plant piping subjected to an IGSCC environment is either carbon steel or L grade low carbon stainless steel with the exception of a shear plug in the Standby Liquid Control Syste h
All Reactor Coolant pressure boundary material complies with NUREG 0313 Rev. l.
All balance of plant ASME piping complies with NUREG 0313 Rev.
1 ex-cept when the operating temperature is less than 200 degrees F or when the operation period at temperatures greater than 200 degrees F
is less than 1% of the design life.
The inspector reviewed Safety Evaluation Report, NUREG-1047, sections 4.5, 5.2.3, 5.3. 1, and 6. 1. 1 which accepted the plant material selection.
On the basis of the required NDE and pressure testing in conjunction with the control materials in IGSCC environments, this item is closed.
IE BULLETIN 76-06, Stress corrosion cracks in stagnant, low pressure stainless piping containing boric acid solution at PWRS.
The inspector reviewed GE letter NMP-2-3039 that analyzed the Standby Liq-uid Control System (SLCS) characteristics because the stainless piping contains a boron solution.
The analysis considered industry observations, piping design, control of chloride content, and control of piping stress levels.
The analysis determined that the SLCS piping is not susceptible to stress corrosion cracking.
The instituted measures are appropriate pre-ventive measures for the condition identified in the Bulletin, this item is closed.
IE BULLETIN 83-06, Nonconforming material supplied by Tube-Line Cor-poration facilities at Long Island City, New York; Houston, Texas; and Carol Stream, Illinois.
Corrective actions for Tube-Line materials has been addressed by Construc-tion Deficiency Report 83-00-09.
Based upon the closure of CDR 83-00-09 in section 3.b of this report, this item is similarly closed.
During the inspection period, the inspector conducted inspections and in-terviews in response to allegations presented to the NRC.
The inspector and licensee actions resulting from the allegations are noted below:
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(RI-85-A-111):
The NRC was informed that SWEC personnel had been used to inappropriately generate RCI Quality Assurance records.
The inspector reviewed the following RCI documents.
NMQAI-10-1, "Instruction for Quality Control Inspection" NMQAI-17-2, "Instruction for Review, Turnover, and Supplementing Required Records" Surveillance Inspection Report Nov 85-72.
Quality Control Prepackage Records Review Checklis ~
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The inspector was informed that SWEC Level II QC inspectors had per-formed prepackage reviews of RCI work packages and had provided prob-lem descriptions on RCI Surveillance Reports.
The inspector was informed that an RCI Level II verified the validity of the concerns noted by the SWEC personnel and then initiated the Surveillance Re-ports for action.
The inspector noted that NMQAI-17-2 provides for a
subsequent Quality review of the work packages by a RCI Level II reviewer.
Based upon the fact that:
the prepackage review was performed by a qualified person in accordance with a written checklist; and the Surveillance Report was not a valid RCI quality document until verified and signed by an RCI Level II; and the entire work package is subject to another document review by a
RCI Level II reviewer; The prepackage review does not violate regulatory requirements relat-ed to Quality Record review.
No violations were identified.
6.
ualit Performance Mana ement Pro ram The inspector reviewed the twenty-fourth Quality Performance Management Program (QPMP) reports.
No violations were identified.
7.
Prep erational Test Conduct The inspector witnessed the conduct of portions of the following preoperational tests.
The inspector verified that the most current test procedure revision was used, that the test prerequisites were complete, that calibrated test equipment was used, that test performance was in accordance with the procedure, that temporary modifica-tions were properly documented, legibility of data entries, control of test interruptions, documentation of test discrepancies and other unusual events, presence of Quality Assurance (QA) personnel and control of QA holdpoints.
N2-POT-32,
"Low Pressure Core Spray" N2-POT-74-2, "Division II Emergency DC System" N2-POT-74-3, "Division III Emergency DC System" No violations were identifie ~ 4(
8.
Preliminar Testin The inspector witnessed portions of the following preliminary tests.
The inspector verified use of the most current test procedure revision, use of calibrated test equipment, legibility of data entries, and conformance with the test procedure requirements.
N2-EPM-V3, "Limitorque Motor Operated Valve Testing Utilizing MOVATS-2000" MD.0100.B03,
"HPCS Diesel Generator Reliability Test" The inspector noted the presence of NMPC Startup engineers, NMPC QA per-sonnel and NMPC operations staff during the performance of the diesel gen-erator reliability testing.
Procedure N2-IOP-100. 1,
"HPCS Diesel Generator" was available to provide the necessary guidelines regarding the diesel operation.
The inspector noted that the test data and performance was in accordance with Regulatory Guide 1 '08, "Periodic Testing of Diesel Generator Units Used as Onsite Electric Power Systems at Nuclear Power Plants."
No violations were identified.
9.
Electrical E ui ment The inspector examined the as-installed condition of Remote Shutdown Panel 2CES'PNL405.
He reviewed the following documents associated with the panel:
Nonconformance and Disposition Reports 11,815 and 13,548.
NMPC Surveillance Report E84-1227 Electro-Mechanics Drawings 42450G Sheet 3,
42453F Sheet 12, 42435H Sheet 8, and 42453H Sheet 9.
The inspector identified that part number 281 was specified as a 1/2 inch diameter screw for the unistrut attachment.
Examination of the panel showed that in several cases 3/8 inch diameter screws had been substituted, without engineering approval, in lieu of the 1/2 inch screws for the unistrut channel connections.
The unistrut channels support vari-ous rotary switches within the panel.
The inspector was informed that SWEC Procurement Quality Assurance had per,formed surveillance of the Re-mote Shutdown Panel installation.
The failure of SWEC Quality Assurance to perform inspections to ensure the proper installation of the Remote Shutdown Panel is a violation of 10 CFR 50, Appendix B, Criterion X.
(85-36-01)
10.
0 erational Pre aredness Plan The inspector reviewed the NMPC Preparedness for Operation Plan (POP).
The POP was developed to assure that all required NMPC procedures have
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been developed, that requisite training has been accomplished and that responsible organizations are prepared for the operation of the plant.
The POP consists of three phases:
Phase I: Consists of a self evaluation by responsible organizations utilizing checklists prepared by guality Assurance personnel.
This'is to be completed by December 1985.
Phase II:
Consists of a presentation of the.POP scope to NRC personnel.
Phase III: Consists of guality Assurance team review of the following areas - Inspection program, design control, maintenance program, sur-veillance testing, test equipment control, review committees, non-licensed training, gA records, document control, procurement, material handling, gA audits, plant procedures, radwaste, radiation protection, fire prevention and security.
Phase III is scheduled to be complete prior to Fuel Load.
The inspector obtained the POP checklists that had been developed for the areas described above.
No violations were identified.
11.
Reactor Core Isolation Coolin S stem Walkdown The inspector accompanied NMPC Startup gA during a turnover walkdown of the Reactor Core Isolation Cooling (RCIC) system.
The installed compo-nents were examined for construction attributes and conformance with draw-ings FSK-27-6D, FSK-27-6B, FSK-27-6C, PID-35A-1, and PID-35B-1.
The inspector noted the turbine bearing oi 1 level sight glass had not been scribed, he was informed that the turbine vendor has been scheduled to perform this prior to the preoperational test.
The inspector noted that NMPC Deficiency Report 9112 was issued to document the inadequate cleanli-ness condition of the turbine end bearing.
No violations were identified.
12'ana ement Meetin s
At periodic intervals during the course of this inspection, meetings were held with senior plant management to discuss the scope and findings of this inspection.
An apparent violation of NRC requirements was discussed with licensee plant management during an exit meeting held'n November 26, 1985.
Based on the NRC Region I review of this report and discussions held with licensee representatives on October 18, 1985, it was determined that this report does not contain information subject to 10 CFR 2.790 restriction F