IR 05000413/1993025
| ML20057E971 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 09/20/1993 |
| From: | Casto C, Hunt M NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | |
| Shared Package | |
| ML20057E967 | List: |
| References | |
| 50-413-93-25, 50-414-93-25, NUDOCS 9310130438 | |
| Download: ML20057E971 (11) | |
Text
.
-
.
.
[/p mec,g o
UNITED STATES NUCLEAR REGULATORY COMMISSION-t HEGloN il
'
'
..
%,
101 MARIETTA STREET, N.W., SUITE 2900
.E ATLANTA, GEORGIA 333234199
%,.....f'
,
Report Nos.: 50-413/93-25 and 50-414/93-25
Licensee: Duke Power Company 422 South Church Street
.
Charlotte, NC 28242
,
'
i Docket Nos.: 50-413 and 50-414 License Nos.:
NPF-35 and NPF-52 Facility Name: Catawba 1 and 2
-
Inspection Conducted: August 30 - September 3, 1993
,
Inspector:
lh
& /d,
9/20/73 M.D. Hunt Date Sisned Reactor Inspector l
Accompanying Inspector: M N. Miller Approvedby:[
- I 'o 9/2ev9 7
,
Charles A. Casto, Chief Date Signed Test Programs Section l
Engineering Branch
'
Division of Reactor Projects
!
SUMMARY
,
Scope:
This routine, announced inspection was conducted in the areas of design changes and modifications, and engineering support activities.
Results:
No violations or deviations were identified.
In the areas examined the inspectors determined that the licensee has a strong technical support staff of knowledgeable and experienced engineers.
The licensee implements an effective modifications program that allows corrective actions to be taken in a timely manner.
9310130438 930928 O
PDR ADOCK05000413[Q d
G PDR
.
REPORT DETAILS 1.
Persons Contacted Licensee Employees
- B. Brewer, Electrical Engineering, Project Manager T. Crawford, System Engineering Manager
- J. Forbes, Engineering Manager
- J. Lowery, Compliance Specialist
- W. McCollum, Station Manager
- K. Nicholson, Compliance Technical Assistant J. Stackley, Component Engineering Manager
- J. Thomas, Electrical Engineering Manager P. Ward, Document Control Supervisor Other licensee employees contacted (turing this inspection included engineers, operators, security force members, technicians, and adminis-trative personnel.
NRC Resident Inspector R. Freudenberger, Senior Resident inspector
- P. Hopkins, Resident Inspector
- J. Zieler, Resident Inspector
- Attended exit interview Acronym and initialism used throughout this report are listed in the last paragraph.
2.
Design Changes and Plant Modifications (37700)
a.
System Engineering The System Engineering (SE) Group is a part of the Site Engineering Organization. The SE group was staffed with 33 experienced engineers and supervisors from the former Projects and Performance Groups. The SE group was divided to five sections with one section being for support. The five sections and their major system responsibilities are:
-
Reactor Engineering Section (seven personnel) - Core physics and fuel handling.
-
Primary Systems Section (seven personnel) - NSSS (nuclear steam supply systems) systems, ECCS (emergency core cooling systems), Fire Protection, and Component Cooling.
'
-
Secondary Systems Section (nine personnel) - BOP (balance of plant), Service Water, Emergency Diesel Generators, Engineering Safeguards Testing, and Chemistry.
.
.
-
-
Programs Section (eight personnel) - Inservice Testing, Leak Rate Testing, D/P (differential pressure) Testing for GL 89-10 Valves, Pump and Valve Inservice Testing,
Ventilation Systems, and Radiation Monitoring.
-
Support Engineering (one engineer) - special system projects.
The inspectors reviewed the System Engineer Technical Support Program which lists the following requirements and responsibilities for each system engineer:
-
Develop design basis knowledge
-
System testing and test procedures
>
-
System trending, monitoring, and walkdowns
-
Root cause and problem solving
-
Track system availability
-
Support and review all modifications
-
System team leader for all system items
'
The function of the SE is to manage activities related to the assigned system to maximize the performance, availability, and reliability of the system. This involves maintaining an overview of all activities listed above related to the system. Also, as
'
the technical expert for a system, the SE provides technical input to support major modifications, initiates minor modifications, evaluates test data for adequate system performance, and participates in problem resolutions to ensure a system meets required design function. The inspectors reviewed a MEMO Report for Engineering's " Top Ten" Third Quarter 1993 work items, dated August 10, 1993. The work items included safety system availability, thermal performance, Steam Generator (S/G) tube degradation, prioritizing modifications, D/P valve testing, fuel reliability, service water audit, and reduction of Station Problem Reports (SPR) and Problen Investigation Process (PIP) reports.
The PIP program is a new method to replace SPRs for identifying, reportino and track.ng station problems and deficiencies.
The inspecto r
exed the backlog for the SPRs and the licensee's justificttion for the open QA-1 (quality assurance notation for safety systems) items. There were 42 open QA-1 items that had either minor or no safety significance. The licensee
'
corrects safety significant and operability problems immediately.
j i
j
_ _ _ _ _ _
i
-
.
.
.
l
The inspectors reviewed the SE list of design documentation in the Technical Support Program for the Auxiliary Feedwater System that included the following:
-
Design basis specification (DBD)
-
System test acceptance criteria
-
Probabilistic risk assessment (PRA)
-
Design drawings
-
Technical specifications requirements
-
Licensee commitments
-
Final Safety Analysis Report (FSAR) items l
-
Safety evaluation reports (SER)
-
Operations procedures
-
Abnormal / emergency procedures
-
Periodic test procedures
-
System and Operations Support Group test procedures
-
Preventative maintenance procedures The inspector concluded that the SE Group was adequately staffed with knowledgeable engineers who assume ownership of their systems, actively participate in identifying and resolving system technical issues, and respond to engineering technical issues in support of systems operation.
b.
Component Engineering The Component Engineering (CE) Group is part of the site engineering organization for technical support.
Previously, CE was the Maintenance Engineering group and was in the maintenance department. The group's main function of providing support to the maintenance department has not changed.
CE has the programmatic lead in the technical support program for generic components and progratn.
For example, valves are generic components and there are several valve programs such as the
" check valve program" and the " motor operated valve program." In addition to components, CE also has responsibility for reviewing station problem reports (SPR) that result in minor modifications.
In addition to components, the two CE Instrument and Electrical Sections have system responsibility for most of the I&C systems,
.-
l
,.-
l
such as Reactor Protection and Nuclear Instruments to name a few.
The CE is also responsible for initiating minor modifications, temporary modifications, test procedures, maintenance procedures, and issuing yearly technical reports (self assessment) for each of their activities.
CE has a total of 53 technical personnel assigned in five sections.
Each section has an engineering supervisor. The CE
.
also provides engineers to the Duke Engineering Services Inc.
l (DESI) Group. DESI provides engineers for service outside CE to l
other Duke facilities and other utilities. The inspectors examined each section to determine its function and staffing I
requirements.
In addition, the inspectors verified that each
,
section was performing its assigned duties. This verification was performed by reviewing lists and work packages of minor modifications completed during the last outage and the minor modificatior.s prepared for the up coming outage. The work history for each component was stored in a comprehensive computer
data base. This work history data base was also used for trending. The inspectors reviewed the components and areas of responsibility for each of the sections to verify that the Component Engineering program was being satisfactorily implemented in a timely manner. The areas of responsibility for the sections are listed as follows:
-
Non-Rotating Equipment Section (eight personnel) - all station components that are nonrotating such as heat exchangers, piping, hangers, snubbers, inservice inspections, hydros, erosion / corrosion program, code issues, steam generator maintenance, reactor head work, and fuel handling.
In addition to the general review, the inspectors examined the following items-Hydrostatic Test MP/0/A/7650/88, Pressure Testing of
ASME and ANSI Piping Systems and ASME Section XI.
Hydrostatic and Pneumatic Test MP/0/A/1720/015,
Pressure Testing of Class A, B, and C Piping.
Service Water Corrosion Inspection Manual.
-
Rotating Equipment Section ( twelve personnel) - all rotating equipment such as pumps, compressors, motors, seals, balancing, infrared thermography, lubrication, oil analysis, vibration analysis, predictive maintenance and the welding program.
In addition to the general review, the inspectors examined the following items:
Predictive maintenance PM-2 program for lubrication,
oil analysis, vibration, infrared, and balancin.
,-
PM-2 computer program, Mastertrend V2.62, and the
trending results for vibration.
-
Mechanical Valve Section (eleven personnel) - all types of valves, all types of valve operators, positioners, valve limit switches, Limitorque operators, regulators, check valve program, and the GL 89-10 motor operated valve program.
In addition to the general review, the inspectors
!
examined the following items:
Motor operated valve program for GL 89-10.
- CFARs (Component Failure Analysis Reports).
-
Instrument and Electrical (I&E) Section (21 personnel) -
There are two I&E Sections.
Both Sections have components
':
and I&C systems. The I&E Sections are the only sections in CE that have system responsibilities. One section has the high voltage (480 V, 4.16 and 6.9 kV) power distribution system. The other section has the low voltage 120 VAC and the DC power system including the batteries.
Both sections have the remaining electrical and instrumentation divided between them.
The inspectors concluded that CE was a well managed group containing knowledgeable experienced engineers and technicians.
CE performs a needed and valuable service supporting the plant and the maintenance department with their expertise in components,
systems, and dedicated programs. CE allows generic problems across system boundaries to be identified and corrected in a timely manner.
,
i The inspectors reviewed the following minor and temporary modifications developed by Component Engineering. These modifications were examined to determine if the controlling administrative procedures were followed and a 50.59 safety
evaluation was performed.
Temporary Modifications 9304612801 - Replace Pressure Switch ISCPS5271 With Model DPS-7233-153 (Weather Resistant Type)
9206635201 - Install Fused Jumper 2TB-AHU-4 9209359001 - Open Link F-33 In Auxiliary Feedwater PTCP To De-energize Solenoid Valve ISA-SV-5020 9303473301 - Install Bussman Fuse P/N ABC-7 In Monitor Light Panel System Train B Cabinet IMLCB
,.
.
Minor Modifications
'
l CE-4017 WR-93006543 - Replace Valve 2CA-69 With 02H-248 CE-4023 WR-93006988 - Replace Valve 2BB-88 With 9J-561 CE-4163 WR-93022532 - Add New Valve 1NI-482 Downstream Of
'
1NI-210 CE-4229 WR-93029811 - Replace Valve IND-84 With New Item Number DMV-876 I
i
-
The inspectors verified that the above modifications were developed in accordance with the required procedures / drawings and
,
the 50.59 safety evaluations were performed satisfactorily.
The inspectors concluded that the licensee has a good program for minor and temporary modifications. The inspectors also concluded that CE does an effective job of supporting maintenance by
!
identifying, tracking, and resolving problems.
l c.
Design Changes and Modifications
Modifications for Catawba Nuclear Station (CNS) are controlled by l
the CNS Modification Manual which describes the processes used to
'
identify and perform modifications to systems, structures, or components. This includes the assignment of personal
responsibilities and the methods for processing minor, temporary, and permanent plant modifications. The manual contains guidance for the development of post-modification testing requirements and procedures. The manual is specific in the exclusion of core design activities, plant switchyards (boundary breakers are indicated),
and specified commercial facility structures and offices type areas at the nuclear sites as part of CNS modification program.
The inspectors selected modifications which were performed during the last refueling outage for each unit to review in part the items listed below to: (1) determine the adequacy of the 10 CFR 50.59 evaluations performed; (2) verify that the DCPs were reviewed and approved in accordance with TS and applicable administrative controls; (3) verify the subject modifications were installed (for those that could be physically inspected) in accordance with the DCP package; (4) verify that applicable plant operating and design documents (drawings, plant procedures, FSAR, TS, etc.) were revised to reflect subject modifications; (5)
verify that the modifications were reviewed and incorporated into the operations training program as applicable; and (6) verify that i
post modification test requirements were specified and that adequate testing was performed. The following modifications were reviewed to determine that various items denoted above were performed.
j
i
' '
.
!
CN 11149 - REPLACE D/G NON-EMERGENCY SHUTDOWN LOGIC
!
'
The inspector verified that the requirements of the modifications were defined and the various engineering
assigntents which included the electrical design / panel
!
modifications, the seismic evaluation of the modified panel, and post-modifications testing were performed and
documented. The inspectors examined the modified panel to
'
verify the as-built configuration drawings matched the field
-
installation.
CN-11272/00 & 11242/00 - INCREASE THE TORQUE SWITCH BYPASS i
SETTING FROM 5% TO 50% i 25% FOR GATE / GLOBE VALVES AND
,
90% 1 5% FOR BUTTERFLY VALVES The inspectors reviewed the 10 CFR 50.59 evaluation and the reasoning for the change which was sound. The post-mod
testing was accomplished by counting the number of handwheel turns that equaled the setting required and verification that the indicating lights were energized at the proper valve stem position.
CN-11257 - REPLACE HEAT EXCHANGER ISOLATION BUTTF.RFLY VALVES i
'
IN THE NUCLEAR SERVICE WATER SYSTEM AND COMP 0NEP4T COOLING WATER SYSTEM WITH MORE RELIABLE VALVES.
.
The final scope document contained adequate detail to describe the purpose /cause for replacement, assigned project task descriptions to each engineering section involved and a i
functional description of each valve. The 10 CFR 50.59 evaluation was detailed and considered the various functions of the valves in making the judgment that no unresolved
,
safety questions existed.
CN-11247 - REPLACE OVERSPEED MONITOR FOR TURBINE DRIVEN AUX FEEDWATER PUMP
!
The scoping document was detailed and assigned the various aspects of the modification to appropriate engineering discipline. The new components installed by this modification were evaluated for conformance to the Equipment Qualification requirements. The inspectors reviewed the control board modification and verified that post modification testing was performed per the monthly surveillance tests of the Auxiliary Feedwater Pum.
-
.-
.
CN-20574 - CHANGE THE POWCA SOURCE FOR LO-LO VCT TANK SWAPOVER LOGIC RELAYS The purpose of this modification was to provide a reliable source of power for these NV relays. This involved connecting the relays directly to the process control system. All the changes were documented and appeared to have been in accordance with required procedures.
Due to the location of the wiring modifications, no attempt was made to examine the as-built configuration.
CN-20646 - REPLACEMENT OF VALVES 2NI-95A AND 2NI-360 AND THE ADDITION OF VALVE 2NI-481 This modification included special installation instructions in addition to the required seismic reports, 10 CFR 50.59 evaluations, drawing changes, and the FSAR revision.
CN-21320 - REPLACE EXISTING DEGRADED VOLTAGE RELAYS WITH HIGH ACCURACY ITE 27N RELAYS This modification provided for the installation of relays with a closer pickup ratio to preclude unnecessary actuation of the undervoltage protection system under certain conditions. All required verifications were completed. A special effort was made by the staff to insure that the post-mod test verified and proved the system operational.
In adCition to the CNS Modification Manual the inspectors reviewed the Engineering Document Manual which provides specific
..
information on the responsibilities and processes associated with
engineering documents which include calculation / analysis, drawings and design specifications. This manual is one of the documents that further defines the engineccing activities as directed by the Duke Power Company Nuclear Policy Manuals which contain the Nuclear Systems directives.
These directives provide the minimum requirements intended to provide consistency between the nuclear sites in meeting licensing requirements. This manual is a corporate document and is further supported by the site modification manuals.
After review of the modifications listed above, the inspectors concluded that the licensee has an effective and well controlled program for the modification of Catawba Nuclear Station.
Within this area no violations or deviations were identified, d.
Drawing Configuration Control The inspectors examined the drawing control process to evaluate the issuance of drawing changes that reflect various plant changes and modifications.
The purpose of this review was to evaluate the
'
.-
licensee's methods for assuring that the various site organizations were in possession of the latest issue of controlled drawings reflecting the as built plant configuration.
All change notices and revised drawings are issued from the document control center. Distribution is designated by predetermined distribution lists. The specific distribution lists to be used by document control is determined by the group responsible for issuing the drawing revision or change notice.
The inspectors noted that there was an electronic receipt acknowledgement required by the document control center for the designated groups to verify that they had received each drawing
!
transmittal. A followup program was used by the document control group to insure that the intended groups receive the drawing issues within a certain time.
i The inspectors reviewed control room drawings to verify that information existed that reflected the latest and current plant
,
configuration. The control room drawings are reviewed by
,
knowledgeable personnel and the changes are highlighted on drawings which indicate a change that would impact on the I
operation of the unit. Drawings were selected which had been stamped indicating that a change existed against the drawings.
These changes were identified by a stamp which contains the modification number and indicated that information such as drawings or sketches covering changes against the drawing were on file in the control room, but had not yet been incorporated into the drawing. The following drawings with changes were reviewed:
'
CN-1578 - 1.0, 1.1, 1.4, 1.5 CN-1593 - 1.1 CN-2593 - 1.1 CNEE- 0147, 0247 CN-1574 - 1.1, 2.1, 2.2 CN-1575 - 1.1 CN-2575 - 2.0 CN-2576 - 3.0 The inspectors also reviewed the Instrumentation and Control List
- 5 which had a temporary modification indicated, and a vendor manual which was marked to indicate a substitute.
The inspectors did not identify any drawings that were not at the latest revision level. Based on the documents reviewed, the promptness in retrieval, and the correctness of revision levels of drawings, the inspectors concluded that the licensee has an effective document control system.
.
-
.*
.
3.
Exit Interview The inspection scope and results were summarized at the conclusion of the inspection with those persons indicated in paragraph 1.
The inspectors described the areas inspected. Although reviewed during this inspection, proprietary information is not contained in this report.
!
Dissenting comments were not received from the licensee.
4.
-
Component Engineer CFR
-
Code of Federal Regulations CNEE
-
Catawba Nuclear Electrical Engineering CNS
-
Catawba Nuclear Station DCP
-
Design Change Package DS
-
Design Study FSAR
-
Final Safety Analysis Review kV
-
Kilovolts MOD
-
Modification MP
-
Maintenance Procedure NPF
-
Nuclear Power Facility NRC
-
Nuclear Regulatory Commission NV
-
Nuclear Volume Control System
!
NV
-
Chemical and Volume Control
'
-
Problem Investigation Process RC
-
-
Fire protection i
-
Residual Heat Removal System RN
-
Nuclear Service Water SE
-
System Engineer
'
SPR
-
Station Problem Report TS
-
Technical Specifications WR
-
Work Request i
l
.